HD drive flanges for puma 90

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Originally Posted by jackdef90

Well, As usual small questions turn into large discussions ha :D
With the stock drive flanges I don't really see those little black rubber caps holding in or forcing any grease down the splines.
I'm going to purchase a set of hd flanges for front and rear, although it seems most people only change the rear set? Am I wasting my money purchasing them for the front?

Jim, after hearing what you write about mags , Will the rear flanges threaded caps fit with the stock 16" alloys fitted to 2.4 Pumas?

Thanks

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As mentioned...
*if upgrading to complete HTE branded drive flanges and axles (HTE rear axles), machining the cap down a few mm (on the threaded outer end) allows the plastic centre cap to fit.

*So machining the rear caps as the rear are a wider width drive flange (longer splines) this allows the plastic cap to fit.
*Fronts if only changing the drive flange is a standard width drive flange (so the plastic cap fits, no mods)
*If upgrading to heavy duty drive flanges and keeping standard axles, then using the standard width drive flange, then the plastic cap fits (front & rear)
I only recommend this upgrade on brand new Defenders (as in there is no wear on the flanges/axles yet).

As already mentioned I only know this for the HTE brand heavy duty axles/drive flanges.

Regards
Daz

Daz,
Iam not upgrading my axles, sticking with standard ones, as I don't think it's necessary with the size tyres that I run and mods on my vehicle.
However I do want to upgrade the drive flanges,
why would you only recommend this mod to new defenders? , mine is a 2010 90 with about 75000 kms on it, is there some reason upgraded drive flanges shouldn't go on axles that aren't brand new?

Quote:

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Originally Posted by jackdef90

Daz,
Iam not upgrading my axles, sticking with standard ones, as I don't think it's necessary with the size tyres that I run and mods on my vehicle.
However I do want to upgrade the drive flanges,
why would you only recommend this mod to new defenders? , mine is a 2010 90 with about 75000 kms on it, is there some reason upgraded drive flanges shouldn't go on axles that aren't brand new?

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Well I've had in Defender (puma) with as little as 70,000km's and the axles/flanges are well flogged out already (I have mentioned this in another post (puma upgrades I think)).

Before you buy, unbolt one (or both) drive flanges, slide out the axle/drive flange assembly, get it on a bench and see how much wear is in it all. You may be surprised how much wear there is. Remove the circlip clean both splines up and see if the axles are showing wear.

Fitting a new drive flange to an axle with wear on the splines means you have a reduced surface area between the two spline (as in the splines are only touching in part).

So basically, if the axles arent showing any signs of wear, then yes fit the after market drive flanges.

Regards
Daz

With reference to the axles and drive flanges on Defender puma models, I've had this stuck in my brain and have been checking out every Defender puma model that comes through my door, as in remove one axle and drive flange to inspect.

Two new models with 10,000km (there first service) BOTH had free play on the splines between the axle and drive flange. As I consider 10,000km's to be nothing more than a run around the block, this free play must be as it comes from the factory (tell me otherwise?). Additionally there was already signs of some wear.

One with 30,000km - Significant wear on both the axle spline and the drive flange, there was actually gritty fines on the inside of the flange and the inner hub (I can only think this may work into the bearings).

two others with 70,000km, 100,000km - As expected worn out and both suffered the "clunk clunk" during shifting.

The fronts on all dont seem to suffer the same fate with regards to wear, but the free play is still there. Personally I think this is a set backwards with regards to quality when compared to the previous model TD5, for an otherwise great vehicle.

Regards
Daz

Has anyone tried removing the flanges every 10 K an cleaning them and greasing them with moly grease?
Dazza is right, there is some free pay when the drive flanges are new but not much. My car was not converted to oil filled hubs until after 130,000 Kms, my axles/drive flanges front and rear were still in good condition. But I used to keep the splines and rive flanges clean & lubricated by moly grease in the little rubber cap.

If you can feel grittiness on the splines the damage is already in progress. The grease will work into the splines and if you regularly top up the little rubber cap, you can see it on the inside of the axle when you remove the flange to adjust the bearing. I still have my original grease lubed rear axles and drive flanges in the shed, they look ready for another 130,000 kms.

It's possible the quality of the axles & drive flanges is lower on the modern defenders and that might be part of the problem, but if you see dry flanges & dusty splines and don't act, the subsequent damage can't be blamed on poor materials.
I figure you could remove all four drive flanges , clean them and the axle splines, ( an old tooth brush works well), grease and refit in 2 hours. After that every 5000 kms put a few cc s of moly grease in each rubber cap. Maybe clean and inspect again after 10,000 kms to see how well it's working. I's got to be worth a go, if it can save axle and flange replacement. :) cheers simmo

Just unscrew the caps and have a look,you'll see the amount of grease in the splines. Pat