Any one about to rebuild one of these boxes be aware that I have come across a batch of faulty bearing. I rebuilt the box in February this year after it got noise on the way home from Hervey Bay. It was going great but I had a vibration in the box only with a large load on it ie. 1st Gear or low range and pulling hard. I went to Cooma in march for the 60th and through the high country after that. By the time I got back to home in Scone it was making a racket again. I found, after pulling the box apart that the double ballbearing on the back of the layshaft had chewed itself to pieces. When the new bearing turned up I checked that bearing for any faults. When clamped up in a vice like it would be in the box I measued 23thou of play. This should only be 2 - 3thou!
A call to the supplier (All 4x4) I was told that this was the only brand of bearing I could get. I got a different brand of bearing form All Makes 4x4 which had only 3thou and is now in the box and going great. The brand of the first bearing is also sold by Greame Cooper in Sydney. They come in a Bluey grey box with a picture of a 90 on it and "Made in EU" the good bearing I got was Torrington. So be aware!