Thread: diff upgrade options

KAM have just restarted and all bits and pieces will be available for lockers etc apparently.

Thanks isuzurover...I will stick with what you have done as as u said the clearance issue and reduced clearance on bottom plus I doubt it would be any stronger than yours anyways....Dana 60 front ??? I'm intreagued

Originally Posted by isuzurover

So what broke Brian?

Was travelling along a dirt road up near Burketown in the Gulf country when the diff locked up and I came to a sudden stop. When I looked under to see what had happened, I found a neat hole through the cover on the Sals diff and no oil left in it. Basically it cooked itself until the front pinion bearing melted and fused things together. The pinion had a flat side, several teeth missing from the crownwheel, carrier cracked and everything was a pretty electric blue colour When I stripped it down I found all the crownwheel studs were loose and one of them had come out far enough to snag on the housing and being hi tensile had broken and went straight through the cover and let all the oil out. No sign of any loctite on any of the studs so assume my diff was assembled on a Monday morning at the factory by someone with a fuzzy head.

Brian, I didn't realise the HD front ends came in stock track width too, I always thought they were a 6x6 thing.

I know where one used to be, I just keep forgetting to ask if it's still there.

Originally Posted by rick130

Brian, I didn't realise the HD front ends came in stock track width too, I always thought they were a 6x6 thing.

I know where one used to be, I just keep forgetting to ask if it's still there.

Hi Rick, Same housing only longer both ends for the 6X6. Only the RFSV's got the heavy one. You can modify/shorten the 6X6 housing to suit 4X4 if you can find one and know someone who is competent at doing it. Part number is AYG4319 for the 4X4 and AYG4316 for the 6X6. There are a few around - Rar110 in Brisbane found a brand new one at a LR dealer who used to do army servicing and acquired it for a very modest sum. Last time I checked LR wanted about 3K for a new bare housing. If you know where one is I would advise you grab it - if you dont want it I will take it off your hands.

Originally Posted by c.h.i.e.f

...
i did read awhile ago about a fella that was making an "indestructable" diff by mixing parts from 80series and gu diffs and then chromoly axles,cvs etc etc but cannot remember who it was or where i seen it

...

I have a hybrid front axle assembly. I bought a bent axle without diff from a 105 series cruiser, a 4.11:1 H233B diff centre from a patrol, and picked up a bare 60 series cruiser rear housing from a scrap bin (stronger housing than 80 series).

The swivel balls were removed from the 105 series housing and welded into the 60 series housing after preparing the axle tubes for length and machining for the spigot on the balls. The housing had to be flipped and the flange replaced for the H233B diff.

80 series side gears were fitted to an H233B ARB locker.

Half shafts are 80/105 series, cv's are Longfield 80 series, all stock 105 series from swivels outboard.

Originally Posted by Bush65

I have a hybrid front axle assembly. I bought a bent axle without diff from a 105 series cruiser, a 4.11:1 H233B diff centre from a patrol, and picked up a bare 60 series cruiser rear housing from a scrap bin (stronger housing than 80 series).

The swivel balls were removed from the 105 series housing and welded into the 60 series housing after preparing the axle tubes for length and machining for the spigot on the balls. The housing had to be flipped and the flange replaced for the H233B diff.

80 series side gears were fitted to an H233B ARB locker.

Half shafts are 80/105 series, cv's are Longfield 80 series, all stock 105 series from swivels outboard.

Seems a lot of trouble to go to.
why not just use a 60 series front end complete sans spring perches and shocker mounts with defender mounts welded on ??

Going the 60 would also mean pinion angle problems or castor problems if the nuckles are not cut and rotated like John has had done