Disco rear diff uni joint conversion

[braddles1]

Thats right - get rid of that rubber doughnut!

It would have really helped me if there was a decent thread on this conversion... plenty of others say rip of old and whack in new so though I would share my lessons...

My saga started by blowing the rear diff out playing with Landcruisers :twisted: and then replacing the rear diff with uni conversion with a standard one. So after two weeks of driving with it the wrong way (typical - cant get a uni joint back to front but the disc...) it was flogged and i reverted back to the uni joint.

This is what I did and am proud of my success as I am not a mechanic...

Start with these parts

https://www.aulro.com/afvb/images/imported/2008/06/663.jpg

From the left we have a diff pinion oil seal, mud slinger, washer, spacer (critical bit - part number 539745, confirm before ordering, but is about 12.5mm thick and goes up against the bearing) and four bolt flange of front diff or Range Rover Classic... get the whole front diff as you wont have to read any further and bolt in!

Next, cut the old 3 bolt flange off (i took diff out to work on a bench) by starting with the 3 outriggers, then you should be able to cut around the circumference with your grinder to access the pinion nut inside. It will look like this
https://www.aulro.com/afvb/images/imported/2008/06/664.jpg

pull the oil seal out with a puller or screw driver
https://www.aulro.com/afvb/images/imported/2008/06/665.jpg
and then insert the spacer
https://www.aulro.com/afvb/images/imported/2008/06/666.jpg
tap in a new seal so it sits flush, greasing the outer lip and oiling the inner lip
https://www.aulro.com/afvb/images/imported/2008/06/667.jpg
time for the new and improved 4 bolt flange then washer and nut...
https://www.aulro.com/afvb/images/imported/2008/06/668.jpg
https://www.aulro.com/afvb/images/imported/2008/06/669.jpg
torque the nut up to 130Nm using the flange restraining tool you knocked up earlier
https://www.aulro.com/afvb/images/imported/2008/06/670.jpg

done, hit the tracks and see if it was worth it... spacer should cost no more than $17 if you go to FWD Motors in Yeerongpilly, Brissy.

[specwarop]

So this can be done on the front and rear diffs? And then just use a propshaft from which model rangerover?
Im also having trouble locating a spacer, does it matter what the external and internal diameters are, or is the width the only critical measurement?
Regards

[Cap]

The rotoflex thinggy is only at the rear. One day ill do mine, but I think ill just let Justin Cooper do mine as im likely to break somthing!

[Tyresqueal]

You can now buy a complete kit from ebay - about $350 from memory.

[dullbird]

or just get it off and old rangie from a wrecker and have a spacer made up :) thats what is on mine;)