D21 Navara SAS with falcon rear leaves

[Heath]

Just dont worry about the hooks! beam axled navara,doubt you ever get stuck. Prity much the ultimate 4x4!!!
haha just jealous,like your truck.heaps! good work

I had a mate who used to go crawling with us who had a lux with V6 holden and all the goodie bits. He (GC) used to like having a play on the mak as well on occasion. The last time I went out with him there were also a few old time boys from here with us, and one of them got a bit bogged down on the Nth side, Gc was closest so Mudrut called him over to pull him out, but alas GC had no tow hooks at all. Nick got all upset and started abusing him for having no hooks and GC just looked at him casual as and said "Never needed them, I've never been stuck" .
You had to be there, it was one of the funniest comebacks I've seen.

Classic.

[kbjj]

I gotta remember that

[kbjj]

Well, someones asked, so here goes.
Ummmm....

Front diff housing is hilux with the ends chopped off, tube welded on other side and GQ safari balls machined to fit, running a Prado high pinion head (4.8, shimmed with extra spring LSD), Bj60 axels, and GQ cv's, knuckels, hubs, brakes, etc.

Setting up bump stops accuratly, as needed a reference point for other mounts, positioning etc.

[kbjj]

Bottom two links have 2.5 inch Johnny Joints on ends mounted to torsion bar cross member, with LN130 bushs on diff end. Top link has Johnny Joints both ends now as horizontal separation not great, therefore top link subject to a lot of load (was crushing the LN130 bush). The three links are 44.5mm OD, quarter inch wall pipe, with my own threaded bungs and lock nuts. Well.... I brought the left hand threaded ones for top link.

[kbjj]

The panard rod is a piece of steam pipe with a Landcruiser panard bush on one end (smallish and firm), and a 5/8th heim on the other for free movement.
Steering is factory Safari rods shortened to suit. Pitman arm was custom made for me and crack tested to keep cert man happy. Gave my heated and bent BJ60 one to engineer as template who saw nothing wrong with it, and made new one same way, heated and bent it??? Steering box is Hilux IFS, the one with the longer input shaft section. It has the same input spline as an 86 Navara and Terranos.

Checking 2.5 x 12inch FOA coilover shock mounting position for the umpdenth time

[vvilly]

i dont see the paperclips

[kbjj]

I moved my axel 25mm forward from memory, but have still cut rear of front guards, plus 15mm out of sill, and deliped seam. At full crush and articulation, the only rubbing with 35" silverstones while on full lock, is on the steering box. I doubt I could fit 35" Simex's.

Shock hoops and brace are steam pipe that were bent 180 on those fancy Hydralic bender thingys. I made my own shock heim spacers to allow me to use 9/16" bolts instead of 1/2" bolts with supplied spacers.

[Damz]

This thing is the nuts!!

Im so sick of my navaras steering...

[u13turbo]

That is one awesome navara!!! How much did the beam axle conversion cost all up? ad would it be the same as doing it too a terrano?

[kbjj]

That is one awesome navara!!! How much did the beam axle conversion cost all up? ad would it be the same as doing it too a terrano?

Cost around $3500 to $4000 for parts etc. All the labour and use of a machine shop was free . The pitman arm was made elsewhere to keep certifier happy. Would be a similar exercise to do on a Terrano, except for clearances to body and inner guards, as body sits lower on chassis.
Gbox out again soon to do bearings, if its not beyond repair.

[kbjj]

I brought a clutch kit for my TD27t from Clutch Systems here in Christchurch a few months back for less than $300. The original pressure plate measured 350 on their test rig, and was slipping with a half worn clutch plate. Clutch Systems one measured 400 and their heavy duty one measured 450, which I purchased. I'm more than happy with it.
Just thought someone might be interested

[sibainmud]

I brought a clutch kit for my TD27t from Clutch Systems here in Christchurch a few months back for less than $300. The original pressure plate measured 350 on their test rig, and was slipping with a half worn clutch plate. Clutch Systems one measured 400 and their heavy duty one measured 450, which I purchased. I'm more than happy with it.
Just thought someone might be interested

You would be right there
Mine was custom built too, carbon fibre/kevlar plate + heavy duty pressure plate, but still slips in 4th and 5th high with anything over 16psi boost
Good thing is the reputable company's owner is one of my clients

[kbjj]

I brought a clutch kit for my TD27t from Clutch Systems here in Christchurch a few months back for less than $300. The original pressure plate measured 350 on their test rig, and was slipping with a half worn clutch plate. Clutch Systems one measured 400 and their heavy duty one measured 450, which I purchased. I'm more than happy with it.
Just thought someone might be interested

You would be right there
Mine was custom built too, carbon fibre/kevlar plate + heavy duty pressure plate, but still slips in 4th and 5th high with anything over 16psi boost
Good thing is the reputable company's owner is one of my clients

I'm interested in the carbon fibre/kevlar plate. Is this so it last longer or can it handle some slippage ie: riding the clutch. I know riding the clutch isn't the done thing , but sometimes I want a lower gear

[vvilly]

I brought a clutch kit for my TD27t from Clutch Systems here in Christchurch a few months back for less than $300. The original pressure plate measured 350 on their test rig, and was slipping with a half worn clutch plate. Clutch Systems one measured 400 and their heavy duty one measured 450, which I purchased. I'm more than happy with it.
Just thought someone might be interested

You would be right there
Mine was custom built too, carbon fibre/kevlar plate + heavy duty pressure plate, but still slips in 4th and 5th high with anything over 16psi boost
Good thing is the reputable company's owner is one of my clients

I'm interested in the carbon fibre/kevlar plate. Is this so it last longer or can it handle some slippage ie: riding the clutch. I know riding the clutch isn't the done thing , but sometimes I want a lower gear

jeremy my clutch is a HD kevlar, safari plate with a toyota spline built by the same croud and it still slips alot less now it bedded in a bit more

[sibainmud]

Ok then..........
Auto clutch, Moringside, Auckland.
They build lots of race clutches.
Mind you I have had it in there for a couple of years now.
Still smokes up at the lights and in 2nd too
Talk to Neil, tell him Simon LeBon sent you.
Cheers,
Simon Collett

[kbjj]

Heres a novel. Last Queens Birthday weekend, I broke my transfer case chain 10min's into the 1st track. I replaced it with one from an auto, and truck wouldn't move. Found out the hard way that Terrano auto xfer case has a 30 spline input while the manuel has a 24 spline input. So, out she came again, and after a few choice words with the wrecker (he was very appoligetic), in went the right one.
Two weeks ago, I assumed I had stuffed another xfer case chain, but never checked properly. Earlier, a mate had sorced me an auto gbox and xfer case cheap, and I was planning on swapping the splined input gear of the xfer case with the manuel one from my origanal, broken xfer (I should have just gone ahead with said plan)
At this point, I decided a stronger xfer was needed and dismantled a Safari auto xfer to find a wider, stronger chain assembly. With carefull measuring, hours of hairpulling, and machining, I fitted the Safari auto xfer chain and gear assembly to my origanal xfer case. At the point I was happy how it was going together, I decided to fit this new assembly, (and the 24 splined input gear) to the auto xfer as it was in near new condition. I split the auto xfer case and f@#$ me , what did I find? It already had a wider chain assembly . Admittadly, not as strong as the Safari setup, but well and truely stronger than my origanal manuel setup.
So, you know how I was going to just swap splined input gears in the cheap auto xfer, well thats what I did
Hey... thats not all, today I installed it, only to find nothing wrong with removed one. What a dick.
This is what I found,

Not sure why, maybe setup (as I did do it myself)... but at least I have a stronger xfer case
Heres a pic of my broken Terrano manuel xfer chain on the left, and Safari auto xfer chain, with the modified drive gear and selector setup. The Terrano auto xfer chain, is the same makeup as the manuel, but wider. The Safari auto chain makeup looks to be stronger (physically bigger links and pins although centres the same)

Does anyone know if a Safari manuel xfer chain is different again?

[niblik]

well done on the transfers jeremy! its one of those things that you'll be glad ya sorted down the track.. as for the front crown wheel.. sorry to hear that mate.. hopefull it'll come to a quick resolution..

post up here maybe?

[kbjj]

Popped a cv a over Reefton way a couple of weeks ago (the last time I try foot on brake and gas trick) and when I removed it, found metal flecs in diff oil, so out came the diff. Faark... another crown wheel failure. The top edge of five teeth have broken away and adjacent teeth on there way. A mate reckons its setup related and I tend to agree, as the wear pattern isn't right.
Oh well, a new c&p ordered, and will pay someone to set up correctly so I've got some sort of warrenty. I'm planning on getting axels, cvs and hub gear cryogenically frozen, and adding a strengthening ring to cv. Also might go mechanical locker, still deciding.

[hosehustler]

Popped a cv a over Reefton way a couple of weeks ago (the last time I try foot on brake and gas trick) and when I removed it, found metal flecs in diff oil, so out came the diff. Faark... another crown wheel failure. The top edge of five teeth have broken away and adjacent teeth on there way. A mate reckons its setup related and I tend to agree, as the wear pattern isn't right.
Oh well, a new c&p ordered, and will pay someone to set up correctly so I've got some sort of warrenty. I'm planning on getting axels, cvs and hub gear cryogenically frozen, and adding a strengthening ring to cv. Also might go mechanical locker, still deciding.

Hi Jeremy,
I worked part time for Rick at 4wdacc for a couple of years and can tell ya he is fastidious about diff settings, they have to be set up correctly for both drive and coast, sometimes it's easy (1 hr) sometimes it's hard (4hrs)
the process is...press on pinon bearings with guesstimated shims put pinion into diff, put carrier into housing, blue in....if not right pattern, take carrier out, take pinion out, ad shims, put all back together, blue in again, if not right.......keep repeating prcess until right, can be very time consuming and frustrating but needs to be correct.
Rick is good at it and will do it properly, i've done many but without a press and dial guage i can't help .

[albundy]

Can vouce for Rick, once watched him spend 4 hrs getting my rear diff back correctly. He got it just right though.
Al

[kbjj]

Yeah, I hear you Tim, thanks , I thought I had it right, but obviously cocked something up.
Ricks getting the gears for me, and it's about time I threw some work his way, he's been really helpful and willing to part with info. I wasn't aware of his diff setup expertise, Cheers Al

[wjw]

Rick spent 8 hours on one of my diffs... turns out the chinese C+P I bought the crown wheel was quite a bit thinner than standard. Learnt my lesson, only buy decent stuff now.

[kbjj]

Brought new diff gears from Precision Gear thru Rick 4wd Accessories. Fitted them to an e-locker from an 80's cruiser and modded housing to suit.


Then added more diff protection, a crown wheel inspection bung, tapped drain hole to take a tappered bung, then added bung guard.


E-locker drive unit guard and sump cut


Made a dump pipe and fitted




Rerouted snorkle as has cost me two windscreens when leaning on trees.


Made new windscreen washer bottle (stainless tube) due to new snorkle route


Added 'skid' bar as I have been caught up on stumps and rocks getting between side bar mounts.


Rear drive shaft centre bearing (rubber mounted) has been a problem. When I added falcon leaves, I added a hilux spline to the rear section of drive shaft to cater for more movement, as spline in back of gearbox wasn't enough. I added two 10mm thick discs to both sides of the centre bearing as extra support. Seems to be doing the trick.

[rokhound]

I spy a couple of things there that may or may not have been borrowed from the collective ideas bin.
Re-routing the snorkel like that is a bitch of a job, but well worth it I reckon even it is just so it doesn't look like a pig ugly unit that seem to be found on just about every other home-built unit
I found that the front axle housing horizontial truss did a good job but I added a lot more protection to the diff head housing on the new front axle as just that small Okuku Gorge number we did managed to put a sizeable ding in the housing.

Looking the shizzle Jezza (you'll luv the positivity of the locked ends )

[kbjj]

Yep, pinched your snorkle idea Rok. Only have front locker... at this stage, dangerous for cv's I think, but time will tell.

[ClassicCruiserSpares]

Wow! you have been busy. Diff looks great have you been out and tested the locker? You'll be pleased to get those other wee jobs finally sorted too.
Did the R&P end up being cromolly?

[niblik]

very nice installs guy.. tidy job ya ended up doin on the sump and turbo dropper.. clever wee bit of 'jeremyism' there with the crown wheel inspection port too..

as for the selectable locker... that'll be mint to test out and with ya new cryo'd front axles too chap.. woot...!!!!

[kbjj]

Did the R&P end up being cromolly?

Nah... but Rick did say they were 5 times stronger than factory ones, and I wont break them with my horsepower. I thought that was a big figure to be quoting, but heres hoping its the end of my diff problems.

[badnuz]

i just gotta say i've seen this in action and its a wicked set up that goes very VERY well

[kbjj]

Made a 3 litre fuel tank for chainsaw and mounted inside spare wheel as I hate the smell of fuel getting into camping gear etc.