what is involved in putting a Qaiffe in a JC5?
I understand there is some machining, but what exactly?
does the box need to come apart?
The machining involved in fitting the Quaife diff in a jc5 is only done on the oe crownwheel mate. They machine pockets into it for ball bearings as these retain the crownwheel. It's pressed on and glued on the original.
To fit it in the box, I'll condense the process! Remove box, split box, undo bearing nut for diff, remove diff, refit Quaife in originals place (once crownwheel has been swapped), refit nut and measure preload/end float, tear hair out trying various shims, tear hair out refitting top gearbox casing and finally - refit box!
Piece of piss. Lol