Final drive (differential)

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OFFSET SPHERE 'POT' JOINT-NEW
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Final Drive Assembly
You will need to establish several things before embarking on a rebuild of your final drive:
         
The first thing (and the easiest) is to work out which drive shafts your Mini has.  Rubber coupling (or 'Moulton') drive shafts were used on most Minis up  
until 1973.  The exceptions were the Cooper S and automatic transmission models, which used universal joint (or 'Hardy Spicer') drive shafts up until that
date.  From 1973 onwards, all Minis used offset sphere (or 'pot joint') drive shafts.  The designs of the final drive output shafts and their covers depend 
on the drive shafts fitted.  While rebuilding a final drive on a rubber coupling Mini, you can easily convert it to take 'pot joint' drive shafts if you wish by 
fitting a pair of DAM3114 output shafts and 22G2688 circlips.    
         
The final drive gear also needs to be identified.  This may be achieved by counting the number of teeth on the final drive gear and if you divide that number
by the number of teeth on the corresponding final drive pinion in the gearbox, you'll get the final drive ratio.  If you are unsure that the age of your Mini's
transmission matches the age of the car, you will also need to work out whether you have pre-A Plus or A Plus gears.  A Plus gears were introduced  
on the Mini round about 1982 (at different times on different models...), and have a sharper tooth angle and different pitch making them quieter than, but 
definitely not interchangeable with, the earlier gears.  Looking in the gearbox, A Plus gears can be identified by the presence of a circumferential groove in 
the centre of the teeth, and the final drive pinion on the gearbox mainshaft is machined flush on both sides.
         
The only exception to this rule concerns cars with the 3.444:1 final drive ratio, which received A Plus final drive gears in 1979, a full 3 years before they
got A Plus gearboxes.  So, if you have a 3.444:1 final drive Mini with a pre-A Plus gearbox containing the larger idler gear and 1st/3rd motion shaft bearings
introduced in 1979, the chances are you will have A Plus final drive gears.    
         
Lastly, you will need to identify your differential case.  The case was redesigned in the early 1980s to combat the problem of spinning pinion thrust washers
wearing through it: notches were added to the case to locate anti-rotation tabs on redesigned thrust washers.
         
For those owners indulging in modified or cometition Minis, several flavours of limited slip differential plus a strong cross pin differential are available, to
special order.  Please contact us to discuss your requirements.    
         
Ill. No. Part No. Description Qty. Rqd. Remarks
1 BTA145 CASE, differential 1 Use with plain pinion thrust washers.
  DAM6027 CASE, differential 1 Use with anti-rotation pinion thrust washers.
2 ATA7378 BUSH, differential case 1 Included in differential case.
         
Final Drive Gears, Manual Gearbox
Ill. No. Part No. Description Qty. Rqd. Remarks
3 22G443 GEAR, final drive, 65 teeth 1 4.333:1 ratio (with 15 tooth 22G99 pinion).
  22G370 GEAR, final drive, 64 teeth 1 4.267:1 ratio (with 15 tooth 22G99 pinion).
  22G101 GEAR, final drive, 62 teeth 1 4.133:1 ratio (with 15 tooth 22G99 pinion).
  22G340 GEAR, final drive, 63 teeth 1 3.938:1 ratio (with 16 tooth 22G338 pinion).
  22A401 GEAR, final drive, 64 teeth 1 3.765:1 ratio (with 17 tooth 22A399 pinion).
  22G940 GEAR, final drive, 62 teeth 1 3.647:1 ratio (with 17 tooth 22A399 pinion).
  22A411 GEAR, final drive, 62 teeth 1 3.444:1 ratio (with 18 tooth 22A413 pinion).
  DAM3645 GEAR, final drive, 65 teeth, A Plus type 1 4.333:1 ratio (with 15 tooth DAM3647 pinion).
  DAM3216 GEAR, final drive, 63 teeth, A Plus type 1 3.938:1 ratio (with 16 tooth DAM3218 pinion).
  DAM4779 GEAR, final drive, 64 teeth, A Plus type 1 3.765:1 ratio (with 17 tooth DAM4131 pinion).
  DAM4162 GEAR, final drive, 62 teeth, A Plus type 1 3.647:1 ratio (with 17 tooth DAM4131 pinion).
  DAM2677 GEAR, final drive, 62 teeth, A Plus type 1 3.444:1 ratio (with 18 tooth DAM2679 pinion).
  DAM2806 GEAR, final drive, 61 teeth, A Plus type 1 3.211:1 ratio (with 19 tooth DAM2808 pinion).
  DAM6327 GEAR, final drive, 59 teeth, A Plus type 1 3.105:1 ratio (with 19 tooth DAM2808 pinion).
  DAM5925 GEAR, final drive, 59 teeth, A Plus type 1 2.950:1 ratio (with 20 tooth DAM5927 pinion).
  TCB10004 GEAR, final drive, 58 teeth, A Plus type 1 2.762:1 ratio (with 21 tooth TCC10001 pinion).
         
Final Drive Gears, Automatic Transmission
Ill. No. Part No. Description Qty. Rqd. Remarks
  22A1003 GEAR, final drive, 72 teeth 1 3.273:1 ratio (with 22 tooth 22A1300 pinion).
  DAM7362 GEAR, final drive, 72 teeth, A Plus type   3.273:1 ratio (with 22 tooth DAM7365 pinion).
  DAM4130 GEAR, final drive, 69 teeth, A Plus type 1 2.760:1 ratio (with 25 tooth DAM4128 pinion).
4 ATA7378 BUSH, final drive gear 1 Included in final drive gear.
5 ATA7043 BOLT, gear to differential case 6  
6 ATA7385 LOCK TAB, bolt 3  
7 BTA154 BLOCK, thrust 1 Optional in DAM6027 differential case.
8 DAM6624 PINION, differential 2  
9 2A7062 WASHER, pinion thrust, plain 2 Use in BTA145 differential case.
10 DAM5071 WASHER, pinion thrust, with anti-rotation tab. 2 Use in DAM6027 differential case.
11 22G2583 CROSS PIN, pinion 1  
12 RPS1418 ROLL PIN, cross pin 1  
13 22A373 OUTPUT SHAFT AND GEAR 2 For rubber coupling ('Moulton') drive shafts.
  22A1151 OUTPUT SHAFT AND GEAR 2 For universal joint ('Hardy Spicer') drive shafts.
  DAM3114 OUTPUT SHAFT AND GEAR 2 For offset sphere ('pot joint') drive shafts.
14 BTA101 WASHER, output gear thrust 2  
15 AHU1856 BEARING, differential 2  
16 2A3535 SHIM, bearing, 0.002" (0.0508mm) A/R  
  2A3534 SHIM, bearing, 0.003" (0.0762mm) A/R  
  DAM3108 SHIM, bearing, 0.006" (0.1520mm) A/R  
  DAM3109 SHIM, bearing, 0.010" (0.2540mm) A/R  
  DAM3633 SHIM, bearing, 0.020" (0.5080mm) A/R  
17 88G477 DISTANCE PIECE, with bush 1 Automatic transmission models; for universal joint ('Hardy Spicer') drive shafts.
  CHM166 DISTANCE PIECE, with bush 1 Automatic transmission models; for offset sphere ('pot joint') drive shafts.
18 22G421 BUSH, distance piece 1 Automatic transmission models; for universal joint ('Hardy Spicer') drive shafts.
  2A3538 BUSH, distance piece 1 Automatic transmission models; for offset sphere ('pot joint') drive shafts.
         
Final Drive Output 
Rubber Coupling ('Moulton') Type 
All Manual Gearbox Models Except Cooper S, 1959-73
Ill. No. Part No. Description Qty. Rqd. Remarks
19 CHM85 COVER ASSEMBLY, with bush 2  
20 2A3538 BUSH, cover 2  
21 ADU5738 OIL SEAL, cover 2  
22 GUG705567GM GASKET, cover 2  
23 SH505101 SCREW, coarse thread, cover to gearbox 10  
24 LWZ305 WASHER, locking 10  
25 22A374 FLANGE, output 2  
26A FNZ810 NUT, output flange to shaft 2  
26B ZPS415 SPLIT PIN, securing nut 2  
27 PWZ110 WASHER, plain 2  
28 GCD101 RUBBER COUPLING KIT, output flange to drive shaft 2 Includes one rubber coupling, plus U bolts and nuts.
  QL5000 NYLON COUPLING KIT, output flanges to drive shafts 1 Uprated; includes two nylon and needle roller couplings, plus U bolts and nuts.
29 22A132 U BOLT, coupling to output shaft and drive shaft 8  
30 LNZ205 NUT, locking 16  
         
Universal Joint ('Hardy Spicer') Type 
Cooper S, 1963-71; All Automatic Transmission Models, 1965-73
Ill. No. Part No. Description Qty. Rqd. Remarks
31 22G419 COVER ASSEMBLY, with bush 2 Cooper S.
32 22G421 BUSH, cover 2 Cooper S.
33 AHU1082 OIL SEAL, cover 2 Cooper S.
34 GUG705567GM GASKET, cover 2 Cooper S.
35 SH505101 SCREW, coarse thread, cover to gearbox 10 Cooper S.
36 LWZ305 WASHER, locking 10 Cooper S.
37 88G476 COVER ASSEMBLY, with bush 2 Automatic transmission models.
38 22G421 BUSH, cover 2 Automatic transmission models.
39 22A1616 OIL SEAL, cover 2 Automatic transmission models.
40 22A1612B GASKET, cover 2 Automatic transmission models.
41 SH505081 SCREW, coarse thread, cover to gearbox 8 Automatic transmission models.
42 LWZ305 WASHER, locking 8 Automatic transmission models.
43 22A1152 FLANGE, output, with bolts 2  
44 22A1139 BOLT, output flange to drive shaft 8  
45 LNZ405 NUT, locking, output flange bolt 8  
46 22A1104 SCREW, output flange to output shaft 2  
47 WE600101 WASHER, shakeproof 2  
48 22A1201 WASHER, plain 2  
49 88G493 COLLET, output flange 4  
50 22A1566 RING, sealing 2  
         
Offset Sphere ('Pot Joint') Type 
All Models, 1973 On
Ill. No. Part No. Description Qty. Rqd. Remarks
51 CHM85 COVER ASSEMBLY, with bush 2 Manual gearbox models.
52 2A3538 BUSH, cover 2 Manual gearbox models.
53 ADU5738 OIL SEAL, cover 2 Manual gearbox models.
54 GUG705567GM GASKET, cover 2 Manual gearbox models.
55 SH505101 SCREW, coarse thread, cover to gearbox 10 Manual gearbox models.
56 LWZ305 WASHER, locking 10 Manual gearbox models.
57 CHM167 COVER ASSEMBLY, with bush 2 Automatic transmission models.
58 2A3538 BUSH, cover 2 Automatic transmission models.
59 ADU5738 OIL SEAL, cover 2 Automatic transmission models.
60 22A1612B GASKET, cover 2 Automatic transmission models.
61 SH505081 SCREW, coarse thread, cover to gearbox 8 Automatic transmission models.
62 LWZ305 WASHER, locking 8 Automatic transmission models.
63 22G2688 CIRCLIP, output shaft 2  
64 GCV1102 OFFSET SPHERE C.V. JOINT ASS'Y 2 'Pot' joint.
65 GSV1073 GAITER KIT, offset sphere joint 2 Includes one gaiter, clips and grease.
66 AKF1457 GREASE, sachet, offset sphere joint A/R  
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