Narrywoolan*

Rear End Rebuild 2009 - 2010.

After the clutch drama was over the car decided to vibrate badly when travelling over 80 km/h. So with a bad oil leak already from the pinion shaft and the original flex couplings in a sad state I decided to pull out the whole rear assembly.


With some help from the Morgan Unfortunate we got it out in an afternoon/evening. Below are the results of what was going on in there.

What we’re working on.
What we’re working on.
Car in the garage. Reference shot for rear ride height. It’s too high!
Car in the garage. Reference shot for rear ride height. It’s too high!
Out in one chunk. This is an early rear end and has Hardy Spicer driveshafts.
Out in one chunk. This is an early rear end and has Hardy Spicer driveshafts.
Phil & the complete assembly on the bench
Phil & the complete assembly on the bench
Peter Renou’s leaf spring compressor. Made a dangerous job very safe.
Peter Renou’s leaf spring compressor. Made a dangerous job very safe.
Pinion shaft. Big oil leaks, excessive end float and back lash.
Pinion shaft. Big oil leaks, excessive end float and back lash.
Silicon gunge in the pinion shaft, or how to get through an English MOT!
Silicon gunge in the pinion shaft, or how to get through an English MOT!
Silicon gunge in the pinion shaft, or how to get through an English MOT!
Silicon gunge in the pinion shaft, or how to get through an English MOT!
Note this is an early diff.
Note this is an early diff.
Remains of double row thrust ball bearing
p/no 48704 (SKF  54-205) rare & hard to find!
Remains of double row thrust ball bearing
p/no 48704 (SKF 54-205) rare & hard to find!
Reason for bearing failure was blocked oil way. Excess gasket goo.
Reason for bearing failure was blocked oil way. Excess gasket goo.
Old & new gland nut p/no 38-32546
Old & new gland nut p/no 38-32546
Diff and crossmember fittings.
Diff and crossmember fittings.
Bare differential.
Bare differential.
Inside all was fine.
Inside all was fine.
Crown wheel in good shape, no wear.
Crown wheel in good shape, no wear.
It’s always fun looking for the Lancia date stamp on each part. 1938 shows the carrier has been replaced
It’s always fun looking for the Lancia date stamp on each part. 1938 shows the carrier has been replaced
Ready to go back together. New pinion shaft bearings & silent blocs for torsion bar guard tubes.
Ready to go back together. New pinion shaft bearings & silent blocs for torsion bar guard tubes.
Checking for backlash.
Checking for backlash.
Closeup
Closeup
Torsion bar & rear wheel hub.
Torsion bar & rear wheel hub.
Slightly bent torsion bar.
Slightly bent torsion bar.
Wear from rubbing inside guard tube.
Wear from rubbing inside guard tube.
Torsion bar bearing. Couldn’t find replacements, but very little wear. So just cleaned out and packed with grease.
Torsion bar bearing. Couldn’t find replacements, but very little wear. So just cleaned out and packed with grease.
The difficult to get bearing, 48056.
45d x 78D x 18B
This one rattles like a child’s toy.
The difficult to get bearing, 48056.
45d x 78D x 18B
This one rattles like a child’s toy.
Muck from torsion bar bearing
Muck from torsion bar bearing
New torsion bar clamp rubbers
New torsion bar clamp rubbers
Damage to wheel hub bearing retainer. Someone has used a chisel!
Damage to wheel hub bearing retainer. Someone has used a chisel!
Wheel bearing mess. Not something to think about at 100 km/h. So new sealed bearings for here.
Wheel bearing mess. Not something to think about at 100 km/h. So new sealed bearings for here.
New flex couplings from Cavalitto. 
Also replaced all silent blocs, 10 in all (later types have 14)
New flex couplings from Cavalitto.
Also replaced all silent blocs, 10 in all (later types have 14)
An original flex coupling!
An original flex coupling!
Lifting off the bench
Lifting off the bench
Aligning under car.
Handy motor cycle lift.
Aligning under car.
Handy motor cycle lift.
Torsion bar puller with 8mm bolt & washers.
Torsion bar puller with 8mm bolt & washers.
Torsion bar puller
Torsion bar puller
Place over end of torsion bar and screw in 8mm bolt, adding spacers as bar comes out.
Place over end of torsion bar and screw in 8mm bolt, adding spacers as bar comes out.
All back together, lower ride height. Now have to sort rest of drive line and radiator position.
All back together, lower ride height. Now have to sort rest of drive line and radiator position.
Took her for quick drive around the block. Diff whine on over run!
Took her for quick drive around the block. Diff whine on over run!
From “Servicing The Aprilia” 1937. Some information on working on the rear end.
From “Servicing The Aprilia” 1937. Some information on working on the rear end.