Front Diff
First we marked a line straight thru the locating holes on the perches and along the diff tubes this line is what will help keep the angles all correct, also centre punched the tubes where the locating hole was as a reference point to work off, we marked front and back of perch in case it fell off while checking measurments etc..
Then we proceeded to cut mounts off with an angle grinder trying not to cut into the tubes.
Cleaned up the the old welds with a grinding disc making sure to re-mark our lines if we removed any at any time.
Then measured NT Diff perches locating holes (centre to centre) then measured the WT ones & devided the difference by 2 and remounted the perches to line up centre of this mark, We checked both measurements from the end of the tubes to be sure (it's roughly 150mm from inside edge of small lip on end of diff tubes.) then we tacked one on at a time and lay a straight edge on each one and eyed them up level but kept the main mark on tubes lined up! when happy we welded em up a little at a time so as not to put too much heat into one area! didn't want to warp to tubes in any way. I have also removed and refitted the U-bolt locators as well, the one on the short side we had to cut in half because it rode up on an angle and would not sit properly. Then we rewelded the hump half of it to the pumpkin and made sure that the U-bolts sat straight before tacking or welding in place.
Once all welded and painted we fitted it all up using a WT Drag link and swapped the flanges on the diff and my 1ltr transfer case to NT ones or you could always redrill the WT to NT spacing at the diff if you wanted to? Now the standard 1.3 drive shaft will just bolt straight in. Fit up extended brakelines and bleed brakes, fill diff and transfer and we're all done. Now moving on to the rear.
She's a good 50mm wider each side now as you can see compared to the rear!
Rear Diff
Ok remove rear diff, drive shaft, brakelines as before.
Remove all brake lines from new diff so as not to cut thru when grinding, I removed the hand brake cable set up as mine has a transfer hand brake set up now. Next mark lines on tubes thru centre of perch locator holes and then along perch as well also mark centre of locator same as before.
Then work out new mounting position as with front diff previously and mark and centre punch so as not to lose mark while grinding.
It works out to around 160mm from back of plate on the end of tube.
Cut mounts off again trying not to cut into tubes and move to new location, tack one in place then lay a straight edge on each as done before and eye the two up together.
Then when happy weld in place as before.
Clean up welds with a wire brush and paint.
Then change diff flange to NT one.
I had to change the transfer brake drum to NT 1.3 because mine has a 1ltr transfer but same as removing a flange basically, just unbolt and release hand brake and remove drum. Ok now you can fit rear diff back into car just re-use all previous conponents from before. Once all back in refit WT brake lines a little bending is needed in order to refit and if it's a 1ltr model you'll need to drill out brake line mounts on chassis to around 18mm dia to fit, then bleed, fill etc etc..
refit wheels all done!
Hope this helps a few out with their conversion? Cheers Robb.
