MollyNomad

Well-Known Member
Hey All.. IRD REBUILD SAGA Continues

I’m still here but in a much reduced capacity… in welding wire and ability.

Having spent some time trying to identify a bearing etc and finally
Looking at some video footage I
had made during the disassemble..I identified where said bearing was located. That only took 5 weeks(conservative estimate) Once all the races were installed and the pinion and ‘layshaft’(🤔) pressed together the next step into torque the nut that secures the lay shaft to the pinion. 184ft/Ibs.

Not being able to torque said nut with my fingers looking at an article I found online in ‘Autowotsisface’ regards an ATB diff instal they mentioned a ‘jig’ for that process. So armed with merely those words I set about fabricating said ‘jig’ Not having a picture to work off/plasma cutter etc I raided my LT35 van shelving for box section.. After much brain storming( i.e. ‘Nil’) it became apparent that actual
Brain storming would be needed so everything was ‘shelved’(pun moment) for several weeks. Not being one to sit on a project, 5 months later I decided it was time. So last week I managed to bond together some sections of box section, drill some holes, way too much grinding and a fair bit of ‘cussing’ I still hadn’t progressed much. Booked some time off and mixed in with hospital visits, a funeral and my ex wife giving me her car(as in ownership) I have now ‘finished’ my ‘jig’. It looks nothing like what I envisioned… maybe that’s a good thing. Anyhoo, I attach some photos of how it looks. It’s needs ‘dressing’ and maybe a lick of paint. I intend to keep it once utilised .. need some bolts to tie the centre IRD ‘carrier’ to the mounting end sections. Have ‘hung off my large ‘bar’ and the nut turns..catastrophic failure may be part of the future however. With that in mind some buttresses on the bottom of one of the uprights..

Once torqued the re assembly will continue.

Thanks for reading this far..

Best

M

PS.. ATM the end sections are held in place by screw drivers in the absence of them bolts! 🥸
 

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I'm interested in this. I dropped a known good IRD and damaged the casing so one day might want to move the internals to the casing from a bad IRD.
 
Update on my IRD JIG assembly and an attempt to torque the pinion wheel nut to 184ft/lbs.

I report ‘failure’. I used a 2mm steel plate to fabricate a locking device for the flats on the end of the ‘lay shaft’…Initially the locking device provided enough resistance to the torque application, but failed(not catastrophically) when more torque was being applied. Whilst fabricating the locking device I did consider that 2mm steel wouldn’t ‘cut the mustard’ but decided to just ‘crack on’ in typical Land Rover owner style. Whilst torquing the nut it got to a point were it went ‘soft’ and I know the game was up. Anyhoo today I removed the top of the locking device and reduced the height of locking device mount so I can mount a 4mm steel plate cut to the right profile instead. That steel is ordered and I will re visit this jig and torquing of nuts saga next week when I finish work(away for 5 days). One issue if that I will be ‘under the knife’ on the 1st of May(Thursday) (hand operation/Dupuytrens Contracture) so will only have a day to get stuff done(not easy after driving through the night before finishing) Anyhoo, I would like to get that done if I can… apparently I have a six week recovery period(no work) after the ‘op’… BUMDER!
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I often use an impact gun to tighten diff flange nuts. They often have a crush spacer between the bearings, which need to be compressed to pre-load the bearings. With an impact gun, care is need to tighten them correctly, using just a few impacts at a time, with checking the pre-load between each burst of impacting.
 
I often use an impact gun to tighten diff flange nuts. They often have a crush spacer between the bearings, which need to be compressed to pre-load the bearings. With an impact gun, care is need to tighten them correctly, using just a few impacts at a time, with checking the pre-load between each burst of impacting.
Thanks Nodge..

This part of the assembly has a spacer but it’s solid and not crushable. The two parts(crown assembly and ‘lay shaft’) are pressed together initially(in a press surprisingly enough) Advice that I have read is not to go over board and that the shaft should turn within the housing relatively easily with no ‘tight spots’.. I’m not that good with ‘impacts’ regard judging what’s needed to ‘nip’ up stuff slowly/in a ‘measured’ fashion using my spider senses(non existent in my case) I do like the idea though.. if it’s appropriate in the (IRD) case(😏)

Really looking forwards to getting this process finished it’s been a ‘while’…..😳🙄

Just posted about turbo priming I need to get that done before the IRD is replaced into situ.. as I can defo get to the turbo better as it is with the IRD out.

Thanks again..

M
 

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