How did this happen?!?! Broke right front half shaft on 81' SIII 109 Military 6-pot

With the steering straight ahead the bore of the stub axle must be aligned with the bore defined by the bearing at the end of the axle housing and the spline in the side gear of the differential. This should be checked by a trial assembly without the axle shaft (and sight through the bore) in view of the problems.

Vertically, this is set by the steering arm and the lower taper roller bearing. The steering arm has not changed(?), but an incorrect lower bearing, or foreign material or a burr under the bearing race or the race not pressed fully in will, as will foreign material or a burr preventing the arm from seating against the housing. Note that there are no shims on the bottom.

Similarly, the ball housing is not seated properly on the axle housing, this will cause misalignment.

My guess is either the taper roller bearing is incorrect, or the axle housing is bent.

I've disassembled the right side down to the axle flange. First, the axle shaft slides into the differential very smoothly and correctly aligned.

Secondly, I installed the swivel ball with the proper orientation so that the bottom of the swivel ball with attach to the steering arm and hold the lower swivel tapered bearing. I confirmed that the swivel ball meets the axle flange evenly and there are no gaps between their faces.

Third, I fit the swivel housing starting with placing the lower swivel tapered bearing inside the swivel housing and then seated the bearing, with the steering arm pin attached to the bottom of the swivel housing, so that the bearing is fitted around the lower swivel arm pin.

Fourth, I tighten the bolts securing the lower steering arm to the lower part of the swivel housing so that the bearing is seated properly and is secure (no sloppy movement) to the race located in the lower swivel ball.

This is where the problem occurs. When the steering arm bolts are tightened in order to properly seat the tapered bearing in the race of the swivel ball, it raises the swivel housing to such an angle with respect to the axle shaft that the stub axle/spindle will no longer fit flush against the swivel housing.

I've confirmed this by loosely attaching the steering arm to the lower swivel housing and then attaching the upper pin to the upper swivel housing. When the upper pin bolts are tightened, which does seat the lower taper bearing in the bearing race properly, the swivel housing is raised about 1/2 inch making the exiting axle shaft off center in relation to the center of the swivel housing. Again, when placing the stub axle/spindle onto the face of the swivel housing the stub axle/spindle will not sit flush against the face of the swivel housing and binds the top of the axle shaft.

If I loosen the bolts securing the upper swivel housing pin allowing the swivel housing to lower in relation to the axle shaft (which also unseats the lower swivel tapered bearing) then the stub axle/spindle begins to align properly and will fit flush against the swivel housing.

lt's almost as if the race in the bottom of the swivel ball has moved so that the proper alignment between the swivel housing angle and axle shaft angle are now not the same. The swivel housing is not designed to have any adjustment up or down or side to side when properly tightened to the swivel ball. So this shouldn't be happening. It should be perfectly aligned when the steering arm is properly secured.

Any more ideas? Thoughts? Link to video on YouTube - - YouTube

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Originally Posted by matthamilton

I've disassembled the right side down to the axle flange. First, the axle shaft slides into the differential very smoothly and correctly aligned.

Secondly, I installed the swivel ball with the proper orientation so that the bottom of the swivel ball with attach to the steering arm and hold the lower swivel tapered bearing. I confirmed that the swivel ball meets the axle flange evenly and there are no gaps between their faces.

Third, I fit the swivel housing starting with placing the lower swivel tapered bearing inside the swivel housing and then seated the bearing, with the steering arm pin attached to the bottom of the swivel housing, so that the bearing is fitted around the lower swivel arm pin.

Fourth, I tighten the bolts securing the lower steering arm to the lower part of the swivel housing so that the bearing is seated properly and is secure (no sloppy movement) to the race located in the lower

This is where the problem occurs. When the steering arm bolts are tightened in order to properly seat the tapered bearing in the race of the swivel ball, it raises the swivel housing to such an angle with respect to the axle shaft that the stub axle/spindle will no longer fit flush against the swivel housing.

I've confirmed this by loosely attaching the steering arm to the lower swivel housing and then attaching the upper pin to the upper swivel housing. When the upper pin bolts are tightened, which does seat the lower taper bearing in the bearing race properly, the swivel housing is raised about 1/2 inch making the exiting axle shaft off center in relation to the center of the swivel housing. Again, when placing the stub axle/spindle onto the face of the swivel housing the stub axle/spindle will not sit flush against the face of the swivel housing and binds the top of the axle shaft.

If I loosen the bolts securing the upper swivel housing pin allowing the swivel housing to lower in relation to the axle shaft (which also unseats the lower swivel tapered bearing) then the stub axle/spindle begins to align properly and will fit flush against the swivel housing.

lt's almost as if the race in the bottom of the swivel ball has moved so that the proper alignment between the swivel housing angle and axle shaft angle are now not the same. The swivel housing is not designed to have any adjustment up or down or side to side when properly tightened to the swivel ball. So this shouldn't be happening. It should be perfectly aligned when the steering arm is properly secured.

Any more ideas? Thoughts? Link to video on YouTube - - YouTube

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Unfortunately you have the swivel housing item 6 in the drawing on wrong it is upside down and Left for right the narrow part should be at the top and the oil level at the back. Look at the parts manual and see how the housing fits narrow bit to top so take the right one off and fit to lift hand side with the narrow bit to the top Then do the same for the one you have on the left.
Land Rover Parts - SWIVEL PIN & BALL HOUSING - SERIES LAND ROVER

Hope you get it sorted Gippy

JD should be along soon.

Quote:

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Originally Posted by Gippslander

Unfortunately you have the swivel housing item 6 in the drawing on wrong it is upside down and Left for right the narrow part should be at the top and the oil level at the back. Look at the parts manual and see how the housing fits narrow bit to top so take the right one off and fit to lift hand side with the narrow bit to the top Then do the same for the one you have on the left.
Land Rover Parts - SWIVEL PIN & BALL HOUSING - SERIES LAND ROVER

Hope you get it sorted Gippy

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Gippy, So I've looked at the left swivel housing since I know it is not eating half shafts like the right is. The oil filler spigot is oriented toward the back and the oil spill spigot is on the bottom. Just like the right side is. If I were to take the left swivel housing to the right side I'm not sure what this will accomplish?!?!? I know you said to flip these upside down and move them to the other side, but since the swivel balls mount to the axle flange with a tilt inward from bottom to top (SEE PIC) and the swivel housing takes into account this mounting angle so that when mounted to the swivel ball the outside face of the swivel housing is perpendicular to the ground, simply switching sides and flipping upside down will orient the face of the swivel housing severely up...causing the stub axle/spindle to be angled up with a wheel, that when mounted, would have a severe lean inward from the top.

Am I missing something?

Attachment 189897

From the pictures I am wrong I am confused I thought the outer housing was installed on the wrong side and upside down I can’t tell what is causing the misalignment the ball when fitted correctly should have the bearing axis tilted inward at the top. The outer housing then when installed should have the front face vertical so when the stub is bolted on it is horizontal. As you can see from the attached photos of my vehicle. Is it possible you have the ball on upside down.

Can you give us a bit of history? I mean, is this a new to you car? Could it have been put together incorrectly by a PO, or are you doing maintenance or renewal on a car you have had and driven before? I'm struggling to get my head around that video unless there's a component that is wrong.

From what I can see above, the most likely issue is that the roller bearing is incorrect, although I could be missing something.

Quote:

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Originally Posted by JDNSW

From what I can see above, the most likely issue is that the roller bearing is incorrect, although I could be missing something.

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It would possibly explain the excess freeplay if the bearing was the wrong depth.

It seems that one side has correct alignment, and the other does not. It should be possible to carefully compare everything on the two sides and pinpoint the difference. Even if this involves careful dis assembly of the side that is OK to compare.

Another possibility that occurs to me is that the swivel pin housing (ball) or the swivel pins have been incorrectly machined, although this would seem to be pretty unlikely unless new parts of dubious provenance have been used.