Austarion

Ok, so I finally got around to putting in my 4.6LSD Yay :D

However after all the hard work (never changed a starion diff before) Is it normal to have to pull off the T/tube to get the diff out/in? But that's not my problem.

I got the new LSD in and had it all bolted up, shafts in etc, when I tried to put the blanking plugs from the LSD (alloy plugs that go in the spline part to keep the dust and stuff out) in to the open 3.55 and bugger me, they don't fit.
So I get back under the car and wiggle the CV up and down about 3mm inside the diff??? WTF??? So it would appear that the 4.6LSD still has the big diameter splines that need US style shafts..... :x

When I got the diff from Mark at GT pumps, he gave me another diff to get the splines from and swap them over, however it looks like the diff guy some how has cocked that up!!! And that diff is now MIA!

What should I do now??? All help much appreciated in advance! :beer :beer

I can't help you with the axle sizes, but I can say that I've always had to remove the TT to get the diff in/out.

I've heard from other people that it's do-able without removing the TT, but everytime I've done it, the TT has had to come off.

In fact, I'm about to switch diffs this weekend (from 3.5 to 3.9), so I'll be doing it again. I've managed to get it down to about a 30 min job now.

Yeah, job is way easier for the sake of a couple of extra bolts and TT off.

Spewing about the splines saga...hope you get it sorted soon.

I had to take the diff out again :glare: But fingers crossed I just might get away with a collar around the shaft to take up the slack.........

I wont know until I get it measured up next week now.

Do the splines engage? If not, a collar won't help except to keep it sorta lined up. Spline count will probably also be different with the larger shaft.

Collar won't work

Why not Dave?

The splines engage as far as I can tell! I'll do a count on Monday.

When you look in the side of the diff, The dust cover/ seal looks the same, the spline looks the same, but the part in between that the shaft sits in is just bigger on the lsd. That is why I thought of a collar over the shaft to pack/ space it up and hold the shaft in the right spot.

Does anyone have a Wide body shaft that I could trial fit? Not drive!! Just fit, remember the car has not been tuned yet :( And the diff is out still :(

yeah check the splines, but i'd put money on it being wrong.

if this is the ex pentti diff that mark had, it needs the 6 bolt shafts.

It is :( not the news I was looking for :glare:

I can get you the 6 bolt shafts if you need them...

G'day Charlie, I only need one to try atm, if that is what I need then the diff is not going to be a keeper!
Modified 6 bolt shafts that are a combo of 2 or 3 shafts will not do for a rally car out in the forest.

Unless I use 6 bold shafts and change over to 5 stud hubs! Would that work Dave?? What would be needed to do that? Wide body Control arms?
If so, then what 15 inch wheels would I run??

The 5 stud hubs suit early Ford stud pattern, and Ford rims are easy peasy to get. You don't need to change your control arms though, just the hubs themselves.
As it's a forest basher, get yourself some extra hubs too!

Oh, and you'll need 28 spline axles, and you've attempting to fit 25 spline units, right?

OK I counted the splines........... 2 times. 25 splines on the shaft and 25 in the diff!!!!!

So my diff guy got that part right!

I just cant see how the collar/ sleeve/ bearing housing part next to the spline is bigger then the AU 3.55 diff???

I reckon the difference is between the big and small diff stuff! I'm assuming the small diff donor with the 25 splines probably does not match up with the big diff set up
(even though it has the right number of splines to suit your shafts)!

I would get the 28 splines put back in and get a set of 6 bolt shafts.
The 6 bolt end can be converted to 4! In other words, I would have gone for the right shafts to match the diff and work from there....