I recently got a full gearbox/diff rebuild kit from the uk. I went to install the new planet gears in the diff and they seem to jam up after rotating the shaft half a rotation. Are there different teeth on the later model diffs?. Also when i bolted the crownwheel with two new fibre washers it locked up the whole unit completely... im not really after a locked diff for around town . Has anyone had similar issues?

All the gears have same tooth count, even late Rover ones.
Mine locked up like that once, then I found a thin piece of fibre washer was still stuck on the back of the side gear. Took it off and presto!

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

A diff that I got as a spare if I ever use it had the same thing ie once the crown wheel was bolted down it was really hard to turn the shafts (could just be done) there didn't seem to be anything exceptional about the diff so I concluded it was normal and the difference in wheel speeds on the road caused this locking to break away.

ie it was a very slight limited slip function to a standard diff. Correct me if I am wrong.

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Roads need more corners
A Deluxe(CG13DE), 2 Clubbies(998 and 1275) and 2 Morris 1100Ss

I found the same thing when I rebuilt my diff. Turned out the thrust washers were pushing the planet wheels too far in with the result the diff would lock up. The wear in the cage was also not even, so the lock up depended on where the washer and cage were during rotation. The new washers being used are thicker than standard to allow for wear in the cage. Where the cage is not worn as much as allowed for by the washer - presto lock up. I couldnt get the original washers, and was offerred an option of grinding the housing out to fit. I finally thinned the washers down by hand (difficult) and no longer have the problem

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1275 LS Brisbane

Oh ok, yeah the kit actually came with the newer type thrust washers with the tab, which i carefully took off, maybe they are slightly thicker than the older type?...ill have a play around tomorrow. Thanks for the input

It's worth grinding the diff a little to fit the new style washers in with the lugs. They stop the washer spinning in the diff hemisphere, which is what wears it.

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DrMini- 1970 wasaMatic 1360, Mk1S crank, 86.6HP (ATW) =~125 @ crank, 45 Dellorto (38 chokes), RE282 sprint cam, 1.5 rockers, 11.0:1 C/R.

i agree with the good Doc,,,works a treat,,,keep the tabs & grind the carrier

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No offence intended here but--> anyone writing a book about minis 30 years ago may not have experienced such worn or stuffed-with components as we are finding these days.

You should put your heart & soul into everything you do.