Adaptor shaft

Dang, forgot to count. Back out into the dark.

Definitely 20 splines on the output shaft that I have. Matching my original count on the drive flange.

One thing that gave me a 'heart attack' fiddling around out there was the realisation that the Discovery 1 splines on the input gear (many more than 20 and larger diameter) are different to the SAE10 in the RRC input gear. This seems to negate what I thought might be the need to allow for long spline input gears.

From memory earlier manual Disco 1's were stripping output shafts/input gears due to lack of lube. Later Disco 1's had cross drilled input gears with longer splines, requiring input shafts with longer splines to match.

This makes me wonder if the Disco 1 input gear from a 1.22 ( from memory I think that's what they are) will fit into the RRC transfer case 1.22. If that were possible then you could move away from SAE10 to a higher count longer spline set. I'll test that out tomorrow unless someone else before hand says it doesn't work.

Quote:

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Originally Posted by workingonit

Ancient. So did you get a second Isuzu flange and an old Isuzu MSA output shaft. Then mill the other end of the shaft down to SAE10?

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No !

AM, does your seal run on the shaft or the flange?

I was looking at pics of dougals shaft (one piece, slides over the msa main shaft), and if you could change the way you fit the seal (fit it from inside the box) then the shaft could be removed ( destroying the seal) and replace rather easily, but would require a new seal each time. Just a thought.

Quote:

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Originally Posted by workingonit

Dang, forgot to count. Back out into the dark.

Definitely 20 splines on the output shaft that I have. Matching my original count on the drive flange.

One thing that gave me a 'heart attack' fiddling around out there was the realisation that the Discovery 1 splines on the input gear (many more than 20 and larger diameter) are different to the SAE10 in the RRC input gear. This seems to negate what I thought might be the need to allow for long spline input gears.

From memory earlier manual Disco 1's were stripping output shafts/input gears due to lack of lube. Later Disco 1's had cross drilled input gears with longer splines, requiring input shafts with longer splines to match.

This makes me wonder if the Disco 1 input gear from a 1.22 ( from memory I think that's what they are) will fit into the RRC transfer case 1.22. If that were possible then you could move away from SAE10 to a higher count longer spline set. I'll test that out tomorrow unless someone else before hand says it doesn't work.

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Got a pic of the fine spline input gear? Whats the t/case suffix number?

OK, I've got it a*** about face re the Disco 1 input gear. They are SAE10. Forget my comment above.

The now remembered story.

Few years ago I was going to put a pto hydraulic pump on a late model DIsco 1. The late model Disco 1 had the long spline input gear SAE10. To my surprise when I took the pto cover off to install the pump, I found that LRover no longer cut the pto dog teeth on the end of the long spline input gear ie I could not drive the pump. The earlier short spine DIsco 1 did have the dog teeth on the input gear.

So I bought a long spline input gear with dog teeth from MRAutomotive. However, I never installed it.

Now comes the purchase of the RRC and the decision to convert it to the 4BD1T/MSA combo.

Throw the v8 and gearbox aside without much of a second thought.

Get the Outcast kit which is SAE10 long spline.

Pull out the input gear from the RRC transfer case and put it aside without a second look.

Shove in the MRAuto SAE10 long spline that I now had sitting on the shelf for a few years. Trial fit the Outcast kit. The fit seems fine and the transfer case revolves without trouble. Which seems to answer the question 'yes' you can fit what on the face of it is a 1997 Disco 1 1.22 input into a 1984 RRC 1.22 box.

Come last night I thought I'd refresh my memory as to what a female SAE10 looks like so I grabbed the input gear that was originally in the RRC transfer case. When I examined the spines I thought these are not SAE10 and way too large a diameter for the Outcast SAE10.

So my original RRC transfer case did not come with an SAE10 input gear. I'll put up a photo in a second.

Borgwarner?

Not going to answer your questions until you answer mine :)

Don't worry photo just on the horizon - just got to test Incisors insistence for a photo bucket which I don't have.

Quote:

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Originally Posted by workingonit

Not going to answer your questions until you answer mine :)

Don't worry photo just on the horizon - just got to test Incisors insistence for a photo bucket which I don't have.

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So be it

AM, I'll let you answer your own question, in writing here of course :D

Attachment 89493

Attachment 89494

Attachment 89495

Attachment 89496

The inside of the MSA drive flange - involute anyone?

Attachment 89497

Quote:

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Originally Posted by workingonit

OK, I've got it a*** about face re the Disco 1 input gear. They are SAE10. Forget my comment above.

The now remembered story.

Few years ago I was going to put a pto hydraulic pump on a late model DIsco 1. The late model Disco 1 had the long spline input gear SAE10. To my surprise when I took the pto cover off to install the pump, I found that LRover no longer cut the pto dog teeth on the end of the long spline input gear ie I could not drive the pump. The earlier short spine DIsco 1 did have the dog teeth on the input gear.

So I bought a long spline input gear with dog teeth from MRAutomotive. However, I never installed it.

Now comes the purchase of the RRC and the decision to convert it to the 4BD1T/MSA combo.

Throw the v8 and gearbox aside without much of a second thought.

Get the Outcast kit which is SAE10 long spline.

Pull out the input gear from the RRC transfer case and put it aside without a second look.

Shove in the MRAuto SAE10 long spline that I now had sitting on the shelf for a few years. Trial fit the Outcast kit. The fit seems fine and the transfer case revolves without trouble. Which seems to answer the question 'yes' you can fit what on the face of it is a 1997 Disco 1 1.22 input into a 1984 RRC 1.22 box.

Come last night I thought I'd refresh my memory as to what a female SAE10 looks like so I grabbed the input gear that was originally in the RRC transfer case. When I examined the spines I thought these are not SAE10 and way too large a diameter for the Outcast SAE10.

So my original RRC transfer case did not come with an SAE10 input gear. I'll put up a photo in a second.

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Yeah i knew that workingonit, was just testing you. There is a 26 and 28tooth input gear. And from memory the earlier non crossdrilled gear had wider bearing spacing or narrower cut gears or something like that.