Thread: Fabricated 4WD Diffs based on the Ford 9"

Originally Posted by frantic

How does a patrol modified rear compare to same cost Salisbury(D60) or Ford 9 in?
So if you spend the same which is better. A bloke I know has designed a fully floating patrol Diff and is in the process of sourcing the right Gear to build them for comps.

Im not sure? I have read a few things and seen 1Madengineer (greg) state that a patrol diff has its limits in the bearing sizes and neck down at swivel in the front end. (I think??)

I also Barry at Hi-Tough has made a few 35 spline (same size and type as D60 35 spline) custom axles for Nissans. These may be your mates???

It would be nice to see the local stuff get more support. But as a population and the shear scale of things, we will never compete against the USA for AM support of products. You could literally spend days googling Ford 9 housings, axles, diffs etc form the USA....

Isn't the Patrol leaf ute diff (the big one) about 1.5", full floater and comparable in the CW/P size to the D60?

This is from Isuzurover
http://www.aulro.com/afvb/986713-post42.html

DANA 60
Ring gear - 9.75"
Pinion Diameter - 1.626"
Pinion Splines - 29
Ring gear bolts - 12x0.5"
Tooth width - 1.437"
Ratios available - 3.54:1 - 7.17:1
Axle splines available:
1.7" 40 spline (not stock - all others from factory)
1.5" 35 spline
1.31" 30spline
1.31" 16 spline
NB - Sals is basically the same spec except for 1.24" 24spl axles.

Diff specs - NISSAN H260
Ring gear - 10.25"
Pinion Diameter -
Pinion Splines -
Ring gear bolts -
Tooth width -
Ratios available - 3.5:1 - 4.88:1 ?
Axle splines available - see below

Diff specs - NISSAN H230
Ring gear - 9.2"
Pinion Diameter -
Pinion Splines -
Ring gear bolts -
Tooth width -
Ratios available - 3.5:1 - 4.88:1 ?
Axle splines available - see below

ALL rear axles SEMI FLOATING ?
GQ Patrol 88-98 cab chassis rear 1.51" 37spline
GQ Patrol 88-98 front 1.26" 31spline
GQ Patrol 88-98 rear 1.31" 33spline
GU Patrol 98 on diesels rear 1.51" 37spline
GU Patrol 98 on front 1.26" 31spline
GU Patrol 98 on rear 1.31" 33spline

I'd expect the Dana and fabricated 9's are better systems though.

here is some stuff from Outerlimits:

Outer Limits 4x4 Board • View topic - best budget diffs GU vs 80 vs MOG vs D60

Looking at starting to source parts for these hybrid 9's.

Going by previous comments and recommendations it would seem that ideally I am after a full floater setup.

So, TrueHi9 3rds with 4.11, 35 spline and ARB lockers, aftermarket 9" case with large thick wall axle tubes.

What I can not get my head around is how to use D2 5/120PCD hubs, keep the ABS but run it with D60 steering, cv's etc.

Does anyone have any ideas or know of someone to contact regarding building these for me?

ABS is something I know nothing about.

Originally Posted by Bush65

That is the way I read the NCOP, but not how I read the QLD regs over riding parts of the NCOP.

I will have to check when I have more time, but from memory it is very clear that the 50mm increase applies to the original track, and it is out of the engineers hands to increase it further.

This is an issue for me. I'm resigned to not getting my bushie registered in QLD because of this - a lot of $$$$ in the portal axles.

When I moved to QLD, I bought with me stronger axles based on 105 series Landcruiser, with air lockers and longfield cv's, etc. These were in the bushie before I changed it to portals. I wanted to put these under my 120, and knew QLD was intending to adopt the NCOP. I didn't anticipate they would over rule that part of the NCOP.

So now I still trying to work out what to do to put stronger axles under my 120. Because of other issues, I need a strong rear end to replace the salisbury, which I can't easily use in my case (I don't particularly like it anyway). I could shorten my 105 axle but then I have to depend upon custom half shafts that can't be replaced with stock shafts that can be found almost anywhere. The other option is to get some custom wheels made with much more offset to reduce the track, but that will make my front freewheel hubs very exposed to rocks, and worsen the loads on the steering (scrub radius) and wheel bearings.

If you are right, it will make a great deal of difference to me, but I fear you are too optimistic. I look forward to being corrected.

John, thought you might be interested in this extract from the QLD gov infrastructure site.

"4.2.11 Off-Road and Goods Vehicle Wheel Track
The wheel track of off-road four wheel drive vehicles and goods vehicles (MC, NA, NB ADR
category) must not be increased by more than 50mm beyond the maximum specified by the
vehicle manufacturer for the particular model.
If a solid axle from another manufacturer is used, the wheel track may be increased by 50mm
beyond the maximum specified by the vehicle manufacturer for that particular axle, provided all
other requirements such as clearances and the tyres do not protruding outside of the vehicle
bodywork."

Originally Posted by CJT

Looking at starting to source parts for these hybrid 9's.

Going by previous comments and recommendations it would seem that ideally I am after a full floater setup.

So, TrueHi9 3rds with 4.11, 35 spline and ARB lockers, aftermarket 9" case with large thick wall axle tubes.

What I can not get my head around is how to use D2 5/120PCD hubs, keep the ABS but run it with D60 steering, cv's etc.

Does anyone have any ideas or know of someone to contact regarding building these for me?

ABS is something I know nothing about.

I suspect for the studs you'll be constrained by the D60 side of things.

Up there Buds Customs is who I'd contact.

Im probably missing something here for sure. Rovertracks use to offer a 35 spline upgrade for the Sals rear. At the hub end they would provide a new stub axle (spindle) that was larger dia. This allowed the bigger axle shaft to pass through. The retained the original hubs by, I believe, having them machined to suit a larger bearing. This larger bearing would fit the new stub axle.

So id say maybe new custom stub axles and have the hub machined to suit the appropriate size bearing. This may be a start