disconnect technical questions

[Moots1288]

Looks great

[Trail X]

Looks real good Sean. Couple questions. Will you need shorter installation bolts? I bet they might bottom out in the pan casting with the decreased height of the mounting plate.

If you said it before, I didn't catch it - what material? I assume a AL alloy since you Tig'd it?

Also, your 3D shows you pressing the bearings down a smooth shaft. Did you end up machining in a shoulder to press to? Or are you pressing to a depth? If pressing to a depth, are you not worried about the bearings potentially walking?

When you talk about cutting your own splines, are you thinking about wire EDM? Don't forget the undercut needed inside the splines to retain the CV, that feature is critical to get right.

Thanks for sharing your progress with us!

[DirtyBacon04]

Well if you want it tested in hot/humid/sandy/muddy conditions, I'll be more than happy to guinena pig it for ya

[seantrost]

James good questions.....
yes we had to shorten the mounting bolts as the plate is quite a bit thinner. material is steel.
I hadnt measured the bearing depths yet when I posted the drawing. we are turned a shoulder to press the bearing too.
yep we have explored the wire edm thought...its a hardened piece so Idont think we are gonna be competitive price wise with the current source. so we are gonna have to let that slide.

now for the good part.
It drives no different than stock. absolutly no play in the tripot after install. and my four wheel drive works again.
The bad news. I need a tccm. as the clutches engage fully with no modulation.


Sean

[The Roadie]

I need a tccm. as the clutches engage fully with no modulation.

Do you mean full engagement in A4WD mode? That could be a transfer case failure from low or old fluid. In 4HI, it's designed to lock up.

[Trail X]

Steel eh? Are you worried at all about galvanic corrosion? What gasket material did you use?

[seantrost]

Roady
dont use A4wd after reading the tech docs. It feels as if the tranfer case lockes fully and does not act as a differential between fron and rear axles. I get a hop driving in a straight line. it only takes about 20 to 50 feet for that to happen. I will service the fluids asap as Ihavent done that since iI purchased the vehicle. thanks for the headsup !

James
there is that possibilty of galvanic action, however you have steel bolts holding the original case together and bearings which are dissimiler metals with little corrosion issues noted. I dont think in the grand scheme of things that it will be much of an issue.we used RTV for a sealant.
Sean

[ErikSS]

I don't work with disimulat metals often but I'm wondering... Would some nice powder coat help prevent galvanic corrosion at all?

[seantrost]

Eric,
Yup ! or a good paper gasket.
just something to stop the flow of electrons.
Sean

[Trail X]

It feels as if the tranfer case lockes fully and does not act as a differential between fron and rear axles.

Correct, there is no middle diff on our trucks. In 4HI and 4LO modes, the front and rear prop shafts should always spin at the same rpm.

[ErikSS]

It shouldn't hop in 4wd if your in a straight line. Have you messed with your gear ratios?

[The Roadie]

The driveline could also bind if the tires are of different diameters.

[seantrost]

tires are same diameter, do not know about the gears as I have not done annything with them. However the truck.is second hand to.me.
Sean

[seantrost]

2500 miles with no issues with bearings or seal.
feeling confident that this is gonna work !
Sean

[Lauron]

Hey Sean, any status update?

Ron

[seantrost]

An Update,
4500 miles on it so far and no signs of wear or temp issues.
been in the mud and goofing off in a snow covered parking lot allong with a fairly snowy winter here in ohio.
I am pleased with the unit.
Sean

[seantrost]

Hey guys, just an update, more miles. Hot weather and no problems.
Sean

[navigator]

sounds like a winner.