Diff case swap (again -sorry)

[sogatha]

I’ve read a lot of previous threads on this but I really want to fit a magic wand diff case to a later 4 synchro (remote gear-lever) box I have.
I understand the problem of the bearing holes potentially being misaligned but if, as is suggested, a machine shop can bore them out to align the casings won’t this leave the holes too big for the outer bearing race to fit tightly? Or have I missed something…

[Mini-geek]

You skim the faces slightly to make the hole slightly smaller, then bore it out again..

[Spider]

There's factory standard parts to do this with. That set up uses the gearbox's original remote type diff cap.

[andy1071]

"Usually" (but not always..!) the bearing bores are not the problem.
It is often the side-faces for the output shaft covers, that are the problem.
-You usually get a step between the gearbox and the diff cover side-faces, so you get an oil-leak....

Trial assemble the diff cover;
1. IF you have a step on the side-flange faces, then you will get an oil-leak.
AND, if you put a couple of bearing in, and you get good clamping of the bearing (compare with the original diff cover), then you could 'just' skim the side-faces to match.

2. IF you don't get proper bearing clamping, then you will need to skim the diff cover gearbox-face, and then machine the bearing-bores as stated.
AND maybe skim the side-faces as well.....

Everything is possible..... It's just a question of cost...!