Fitting Hilux RCV CV's into Rover front
I'm after some technical advice and measurements so i have an idea what to look for and consider for fitting Hilux/Toy 40 series CVs into the rover housing (Defender). In essence i'm looking to replicate what Keith offered which is no longer an option. I'll describe the plan and then pose questions.
I plan to source/build a 30 spline rover locker. This can be achieved by broaching a blank side gear or convincing a locker supplier to build it to spec. Brand is yet to be decided but likely ARB on the suspicion that their Hilux locker and Rover locker will have interchangeable side gears (i'm looking into it). Yes i know Jack Mac made a hybrid in the past, but i need someone responsive to a 1 off project. I plan to use RCV 30 spline CVs for Hilux LN106/Toy 40 series with half shafts made to length in 30/30 spline. I will machine a custom bearing spindle to suit the larger 30 spline stub axle and oversized hub bearings. I have done this already for a 35 spline sals. I just need to merge the front bearing spindle shape with the bearing measurements from my 35 spline spindle. I already have hubs machined for the larger bearings (front and rear hubs are the same). Yes i could machine the bore of the LR bearing spindle but i'm not convinced it has enough material to provide the support for the bearing. With the larger hub bearings the OD of the bearing race is larger, thus more material to support the bearing. To cap it off i'll get a 30 spline drive flange made. The end product should be a 30 spline pegged locker, 30/30 spline 300m or HTE half shafts, 30 spline 300m CV, oversized bearing spindle and oversized bearings. Yes it is still has LR C&P and a CV no larger than the LR unit, however RCV warranties their CV up to 40" tyres and pegging will address most of the R&P shortcoming. It will be as strong as you can go in a rover housing, and will be sufficient for my needs.
I have ordered a LR and Hilux bearing spindle for comparison and for the machining drawings. I will borrow a set of Toy 40 series axles/CV's to compare to the LR set. Some of these questions might be answered when i get the Toy and LR side by side, but as stated above, need guidance what to think about when taking measurements.
Questions posed:
1) Does anyone know what machining is required to the brass/bronze thrust washer. Does it need to be machined only for ID or thickness as well (to locate the bell in the swivel). If thickness, is there a spec;
2) Is there a tolerance i should adopt for the interface between bronze washer and CV stub axle? This question is a loaded one. On some images the bronze washer is located inside a forged ring on the bearing spindle and others it sits outside. A search of FTC3154 which is relevant to mine, it appears to sit outside the forged ring.
3) Likewise to the above, do i need to consider the chamfer on the washer to suit the Hilux CV bell. I assume the chamfer has no bearing on the support of the CV but i've been known to be wrong in the past (only once that i'll admit to).
4) is there a part reference for a compatible seal and needle bearing that suits the diam Hilux CV and diam of the LR bearing spindle. Comparing an image of the hilux CV to a defender CV the hilux has a single machined surface while the LR has a wider machined surface (needle bearing) with a step down to a narrow machined surface (seal). I take from that the seal ID will not suit the hilux CV. Since it is custom machined part, technically I can machine to suit a seal rather than shove a square through a round hole. Is there an alternative seal i should consider in a custom seal face arrangement or is it as simple as searching the catalogue for something that suits?
5) in the alternative to the above, the Hilux bearing spindle appears to only have the bronze washer and no roller bearing and inner seal. I assume the hilux set up is oil in the CV and hub bearings. I assume the groove in the washer is an oil feed. Assuming the swivel housing is coming off at some point, is it more convenient to machine the inner of the bearing spindle to suit the hilux thrust washer, machine a drain plug into the swivel and run oil in the swivel and bearings? The patent query: does the thrust washer on the LR bearing spindle (assuming its the outside version) also locate the spindle in the diff housing. the pics would suggest it does but with so many pics that purport to be the correct part # i'm not confident. Other issue is to get the flange face offset correct as between the LR and Hilux bearing spindle so the CV is located correct. I suspect this route will require a custom machined bronze washer to merge the hilux CV support and LR diff housing interface. Just not ideal to go too custom. I would machine spares in the first batch.
6) i'm all ears to hear of a more convenient way to merge the LR bearing spindle design with the hilux CV.
I'll leave it there for now. My head is hurting from over thinking it. I'd prefer if the topic remained focused on what i'm trying to achieve and not splinter off into why bolting a GU or 80 series diff is better. For those tempted by the irresistible urge to defy my request, i've considered and dismissed patrol and 80 series primarily because (i) i would have to live every day knowing i went to the dark side; and (ii) i have a very expensive brand new everything 35 spline dana 60 setup in the rear. If i wanted bomb proof i would go Dana 60 front with dana 60 steering and 8 lug hubs in 35 spline end to end. (i have a sals front housing and done the planning for the rest). I hope that the discussion is helpful to me and for others in the future.
thanks in advance, MLD
MLD
Current: (Diggy) MY10 D130 ute, locked F&R, air suspension and rolling on 35's.
Current: (but in need of TLC) 200tdi 110 ute & a 300tdi 110 ute.
Current: (Steed) MY11 Audi RS5 phantom black (the daily driver)
Gone: (Dorothy) MY99 TD5 D110
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Originally Posted by MLD
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