Shaving Safari front diff

[Shane]

Something I'v been wonting to do for a while,I had to do swivel bearings on one side so I pulled the whole diff out.i marked round the diff first were I was going to cut(that was harder than expected with the diff conters)using cutting disc sliced off bottom,then ended up grinding quite a bit more off.I was going to use 3mm plate,but once Inside diff I found it was made of 5mm.i ended up using 6mm plate,cut a hole in that were the ring gear goes(ring gear sits about 3mm into hole cut in plate,NOT protruding through hole)then welded a small strip of 3mm to cover hole.weld the hole thing up then jam it back in the truck.
With 35" bfgs @ 35psi its about 288mm diff clearance.

The gains not huge by any stretch,but any gain I can get for cheap I'll take.

looking at the pics in Rocks thread,he got alot more off his toyota diffs,which are quite abit smaller to start with

[callum007]

might be a silly question, but can you still get the diff head out again. looks like the plate was tacked on with head already inplace.

[Shane]

might be a silly question, but can you still get the diff head out again. looks like the plate was tacked on with head already inplace.

no welding was done with the diff head in place,I tested before final welding,I didnt test after welding just throw the housing back in vehicle,when fitting diff head couldnt get it in.....few words were said...bother,dam etc as it turned out was just catching on the studs

I see what you mean though,looks like diff head cant come out

[You Get That]

Nice job i allways thought this was a good way of gaining an inch of clearence without going up 2 sizes in tires.
How much you cut off?

[pruggerdore]

good effort. how much do you think you managed to get off?

[rokhound]

Nice job i allways thought this was a good way of gaining an inch of clearence without going up 2 sizes in tires.
How much you cut off?

Here's the man who has it sorted. If you gained an inch, which it looks like you have achieved easily, that is equivalent to going to a 37" tyre, which is what you would have to do in your case.
Good job

[coxsy]

looks like about 25mm off the head

[Shane]

Its only about 18mm going by the ruler(does look like more though)I didnt quite get the plate flat front of plate lower than back,if I had it level would be 22-23mm...dum-ass

still glade I did it,have to do rear one now

Shane

[albundy]

Where's the drain hole going?

[Shane]

Where's the drain hole going?

Lower most diff head stud been removed and replaced with bolt,is quite alot lower than factory one also.