mounting new diffs.

[marmite89]

K so ive got my hilux half stripped and getting ready to start making mounts for my safari diffs. Does anyone know what is needed to b done and if so could someone tell or better yet show me. Thanks.

[derk]

are you coiling the lux or trying to stick leaf spring perchers onto the saf axles?

[marmite89]

Im leaf spring lux so gotta convert saf diffz to leaf spring setup.

[derk]

other than hacking the mounts off the axles and finding a bit of box section to make some perches out of you'll need to have a good measure up to get the axles aligned correctly and you'll have to watch your pinion and caster angles. In a perfect world you'll get your driveshaft angles lined up like the diagram in the attachment but in the real world it never really happens on a lifted old bush truck , if you have to point your pinions up bare in mind they are splash fed lubrication so you may have to lift the filler hole up so you can over fill the diffs with oil, if you rotate the front diff to change the angle of the front pinion you'll change the caster and it'll steer like shit as best case scenario or be outright dangerous and undriveable at worst case scenario so You'll have to grind off the welds and rotate the front knuckles to get back to the original caster angle. Don't give anything too much heat and prolonged welding so you dont have have to worry about any axle housing warping and distortion. Lots of measuring, thinking, internet searching and planning and it should all come out sweet, if your welding is shit grab a couple of boxes of piss and get your mate to come around and stitch everything up for you

edit.. and when you measure up make sure your front D/S isn't going to fowl on the sump or anything going to a Saf high pinion front diff

[mudlva]

Personally i would look at setting up the existing diff up into a jig to hold the spring mounting plate horizontal. Then set up a second jig to create the pinion angle.
On e you are happy with the existing set up remove the diff housing and replace with the y60 housing. Make up your new spring purchase saddles and raise up y60 housing so its the same center line as the hylux unit. Once happy with position rotate housing to get the same pinion angle. All be it will be north or south in relation to the hylux it must be in the same plane as oe.
Now before you start. Chopping and welding you will need a std y60 running on std suspension. Measure the the relationship between the radius arms and front to back on the oe saf. This will give you an idea on where the pinion sits and on where the caster angles are. Place the radius arms onto your donner diff and see iff the measurement off sets is similar to the the oe saf was. If its food start to tack it all together. Ifs it majorly different then stop and look at what needs changing. Remember that caster angle is important as much as pinion. As stated above you may have to alter the caster as well to get it to drive nice.
And using the statement of its only a bushy will not cut it as even a bushy may get up to a reasonable speed especially of beach and farm runs

[danp01]

my mate has recently done this, put safari diffs and axles into his v8 surf.
couple pictures





if you need any help drop me a pm and I can pass on a number.

[mudlva]

How did he mod the hub to take the steering link?

[marmite89]

Cheers for that info mate will keep uz posted and take some pics as I go. I've already been told to give up cause what I'm doing is so much work and effort but I'm learning and I'm enjoying myself at same time.

[marmite89]

Thinking of new approach to my build. Just had it brought to my attention that my hilux ln60 chassis is longer then my surf body so what i am now thinking is flag chassis swap and just solid beam conversion on my surf. Now how hard os that going to b and what sortve misson am i in for?