Dropped the front axle for a sand blast, paint and rebush, no problem until I took of the diff to check the reason for excessive backlash......
Looks like the PO, lets call him Stu Pedd (not his real name), went deep wading without a wading kit, flooded the diff and then must have left it for a while!
Knew there would be problems when I drained the old oil and it looked bad. Found rust everywhere, all the bearing races pitted, adjusters rusted in the caps, diff carried/pin worn (cause of the backlash)....... Thanks to Stu! Thankfully run out was 0.03mm, the backlash an in spec 0.12mm and the crown wheel/pinion look undamaged aside from a little surface rust.
On the bright side, wanted to fit Ashcroft ATBs and now have an excuse for the front. Ashcroft service is fab, ordered AATB with bearings, crown wheel bolts (old lock washer type fitted), pinion bearings and flange first thing Monday. Delivered 09:30 Tuesday!
Diff totally stripped, old bearings and carrier added to my every growing pile of scrap Land Rover metal. Case, wheel and pinion wire brushed and degreased. Just waiting for the 39.5mm slip gauges and will rebuild it Friday. Then refit the front axle this weekend, better than new.
Take a deep breath and then press on with dropping and refurbing the rear axle, hopefully Stu hasn't trashed that diff too, could do without rebuilding the rear diff this year.