The plan……At the moment the rear cover is removed, the top shaft /longer version/ is replaced and the new “stuff” is bolted on, with output shaft passing under front suspension/steering tube.

Now the warm weather has arrived, back in the shed to "Bodge" some more parts.

Had the rear cover and top welded up.
Came to fit the pinion shaft and found it very tight, after some head scracthing, found the rear cover out by 30 thou + see picture below.



The case just fits in the mill so took off some material and the shaft now fits, small adjustment to the retaining plate and shaft now rotates freely.
Need to make a new longer drive flange to locate the pinion shaft / bearing correctly.



Wiil fit 2cv calipers behind the diff, easy access to the pads and less chance of retaining all the dirt.



Transfer box now fitted with triplex chain, need to fabricate rear cover/bearing retainer/oil seal ... and on the engine side fit/make the selector dog and fork...

Now working on the rear diff, while awating some M7 countersunk bolts ? from afar..

So try-out_____ Mounting the Calpers, still quite a lot to fabricate

So this is the rear diff, with on board disks?

Yes, pretty much all the 4x4 conversions use a standard 2cv gearbox, mounted in the rear,drive is through the standard clutch shaft, 4x4 drive selected via engaging 3rd gear.
Did think about outboard discs, not that hard to do mechanicaly. It was done at the front by one of the 2cv race guys, but you need a very slim caliper. Someone sourced them for Willwood? But they would have cost more than I have spent so far on the projectso far....

Need to fabricate/lathe a new Prop flange with a longer tail to fit on the pinion shaft.

However the price of Steel has almost doubled !!!!

Put off spending, so fit the Calipers at the rear end of the diff..

To make the calipers clear the disc, had to mill 1.5mm of the back of the caliper, more bespoke bits.

Nice job, no connection between left and right to keep the calipers vertical?

Not yet, and there will be, I suppose..?