Outer Limits 4x4 Board

Hi guys, have picked up a rangie rear tailshaft with uni's both ends to replace the donut tailshaft on my series 2 diff?. Problem is i can't seem to work out how to get the attachment point on the diff off, it's not bolted on, it has a shiny 15mm diametre X30mm long shaft coming out with an internal thread.
I have a disco 1 but the diffs i believe to be out of a 90's model disco or defender but am not too sure.
How do you remove this and replace with the earlier bolt on universal attachment.
I tried screwing a bolt into the thread and tensioning to see if would screw off both left and right but nothing, then while under tension tried hitting with mallet but still nothing.
Your help be much appreciated.
Cheers

You'll need a slide hammer to remove the pin (if you mean the bit sticking out of the middle of the flange which locates into a bush in the tailshaft). Weld a bolt (that screws into the pin) to something that attaches to the slide hammer.

Or you could try and make a puller that screws into the pin and then pushes off the flange

They can be extremely tight in there, unfortunately, and there is a bolt behind them which holds the flange on to the pinion shaft.

RangingRover wrote:You'll need a slide hammer to remove the pin (if you mean the bit sticking out of the middle of the flange which locates into a bush in the tailshaft). Weld a bolt (that screws into the pin) to something that attaches to the slide hammer.

Or you could try and make a puller that screws into the pin and then pushes off the flange

They can be extremely tight in there, unfortunately, and there is a bolt behind them which holds the flange on to the pinion shaft.

cheers mate, had a funny feeling it was going to be something like that, bloody crazy, why didn't they leave it the same as the earlier models, just undo a lock nut. Any way gets me to the next question, you say there will be a bolt behind which holds the flange, is it a bolt or a nut? will the flange i took of my spare front diff bolt straight on or am i in for a surprise? was told it was a straight forward job but so far not so, don't want to go to the trouble of getting the flange off only to find i can't do what i want to do anyway.
cheers

Any way gets me to the next question, you say there will be a bolt behind which holds the flange, is it a bolt or a nut? will the flange i took of my spare front diff bolt straight on or am i in for a surprise?

90% sure its a 15mm headed bolt up the guts, but I don't remember if there is a thread on the outside of the pinion which would allow the nut from an earlier flange to go on.

this is how I did it. It was ugly, but in the end it wouldn't pull, so I released ti with an angle grinder. I assume you mean a Disco2.

http://www.slunnie.com/coppermine/thumb ... p?album=31

My D1 diff (no longer fitted to a D1) had a 16mm nut (24mm across flats) behind the centering post.
My slide hammer with an 8mm stud was able to pull the centre post out without any grinding.

I have all the measurements for the spacer as well if you need them.

So you reuse the bolt from the D2 flange to hold on the classic RR flange, and just wang a spacer in behind it?

I have all the measurements for the spacer as well if you need them.

I'd be interested, my cousin just bought a D2 and wants to turf the donut.

Pretty much. That spacer comes with the 4 bolt flange, the later flanges were all in one piece.

Don't turf the 3 bolt flange and peg! Post it to me!!!

Slunnie wrote:Pretty much. That spacer comes with the 4 bolt flange, the later flanges were all in one piece.

Don't turf the 3 bolt flange and peg! Post it to me!!!

I've got a 3 bolt flange and peg that I'll never need. Let me know if you can't get one locally.

Measurements for the spacer:
ID = 32mm
OD = 41.2mm
Thickness = 12.5mm

Thanks Guys, you were a great help, especially the photos slunnie, just got back from holidays and decided to have a crack at it with no luck, then jumped on line to see what response you guys had for me and now it all makes sence, i will go back out now and have another crack at it but now i know how it has been put together i'll be right.
Cheers

Heyyy, got the damn thing off, what a strugle, had to do as Slunnie did and use an angle grinder in 3 spots in order to try and loosen it, but it was still a stubborn mungrel of a thing, any way cheers for your help.

Dodgy as all hell, but it's always a winner on that bloody spigot.