PS rear axle install question

[spressomon]

OK...I got the 3rd member back from Sean and got it and the DS axle reinstalled (thought I was home free...right!!! ). However the PS axle only will partially go in...it needs to go in another 1.75"-2" or so and won't. Any words of wisdom? FYI: When I pulled it apart originally I locked the e-locker...however now the DS axle doesn't spin the pinion so I am assuming the e-locker got switched to "off" when he installed the R&P? Would it be OK, while the PS axle, is in as far as I can get it right now, to engage the locker now without harm or not?

 

[spressomon]

Christo and/or Darren:

Ok...took the 3rd member back out since it was clear the axle wasn't going past the outer locker dog clutch plate/spline (MFPITA). The culprit is the outer carrier. Evidently Sean used the 80-series carrier plate (along with the 80-series carrier of course) and inner locker clutch dog and it is approximately .5-1.0mm too small (between the red arrows on the pic below) in diameter to allow the 100 series 32-spline axle to pass through to the splined planetary gear.

Question: In this type of conversion (4.88 into a 100) is it possible to utilize the 100 series outer carrier cap assembly including the 100 series inner clutch? Or will it be necessary to machine the ID of the 80-series inner clutch to 34mm?

Graci in advance!

Dan

 

[spressomon]

OK...for all of you contemplating doing this conversion you can buy me lunch
...the 80 series clutch dog must be bored to allow clearance for the 100 axle. The 100 series carrier cover and clutch will not bolt into the 80 series carrier housing!

When this process has been completed and I am driving the rig sucessfully I will post up the final set of instructions...hopefully within a week or two.

Its too damn bad no one makes actual 4.88 R&P for a 100 series...then all this could have been avoided.

Note to Self: Don't be the first to embark on new territory as it relates to undocumented customization!

 

[hoser]

Spresso--thanks for doing this ahead of me. I owe you lunch!
I patiently wait for your write-up.

 

[montocr]

just retain the hat from 100 diff

That is why you use the case hat from the 100 diff. axle will clear. no machining needed if you do this

 

[spressomon]

That is why you use the case hat from the 100 diff. axle will clear. no machining needed if you do this

Sean at River City Diffs told me this morning the mounting bolt spacing for the case hat is not the same 80 vs 100 series carriers and that was why he used the 80 series case hat. So now we have two conflicting opinions.

 

[spressomon]

That is why you use the case hat from the 100 diff. axle will clear. no machining needed if you do this

That's what we did this morning...thanks!

 

[ats4x4dotcom]

you could of turned some off the axle as well, if really stuck.

Interesting the pattern paste is mainly only one part of the crownwheel, did he check the carrier for runout before bolting on the crownwheel?

[we allow up to 8 thou runout max]

 

[calamaridog]

Its too damn bad no one makes actual 4.88 R&P for a 100 series...then all this could have been avoided.

I can wait