measured old and new CV, both the same, the spacer is to thick... measures 8mm, needs to be 5.5mm... not too sure whats going on as its supposed to be the right part.
anyway the bad news is i cannot get my halfshaft out of my new CV joint, and i do not want to thrash it off... so given there is only 1.5mm axial movement and the shaft cannot botttom out in the CV i will leave it on.... on the other side i will thin the spacer down to 5.5mm and fit that one....

also my overhauled final drive/diff arrived today, i was debating on whether to do a short video in the difference in play between my old one and the overhauled one.. would anyone be interested in this?

You shouldn't need to 'thrash it off'! I open my vice jaws to a bit more than the shaft and then bring the CVJ down smartly onto the top of the vice. CVJ stops, halfshaft keeps going - I have a wooden floor for the shaft to fall onto.
 
just found this thread.... it would seem later TD5 do not need to the spacer :)

http://www.defender2.net/forum/post584474.html

If you look at the parts books for all the axles that use the same basic casing you'll find all sorts of little differences between them - parts seemingly just left out. My approach is to put it back to how it left the factory because we just don't know why a change has been made to a later model.
 

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