Outer Limits 4x4 Board

Thanks to a very bashed in front sumpguard, I've managed to shear off the front diff, bottom mounting lug from the diff housing.

So take a few seconds to have a look - if you can see the leading edge of the diff under the sumpguard then your at risk ( if you can see half the diff then....... )

The sumguard just frankly isn't up to heavy use, its basically a mildly corrugated sheet of steel supported at the edges. A few decent bashes and it distorts quite badly - leaving the diff's leading edge exposed.

I've a new one and am re-enforceing it extensively with a welded "cross hatch" of stiffening ribs and adding a longer skid plate down to behind the transfer.

mine was replaced with 5mm checkerplate about a week after i got my feroza, i made it about 8 inches longer than the standard one ... saved my steering/diff on at least a couple of runs

ive just managed to get my hands on a half sheet of checkerplate to do a skid plate down to the transfer case like your doing.

I'll have a look when I get home to see if I still have the details Mike Henessy drew up for a custom front bash plate. That was a looong time ago

On mine the front bash plate finished way short of the diff- was I missing something on mine? I remember there were captive nuts in it as though there should have been a second section?

BTW I cut a piece of heavy duty right angle to fit between the two rear most mounting points for the front bash plate. It wasn't visible from underneath as the bash plate still bolted over it, but even with the little off roading I did the bashplate was soon moulded around it.

It made funny noises with the diff flopping around under the car

Steve.

Have a look here fellas.
http://www.outerlimits4x4.com/sutra1134 ... t=#1134013

I have posted full detailed drawings and photos.

Beauty, thanks Clint

Gwagensteve wrote:It made funny noises with the diff flopping around under the car

Steve.

Driver was also make "funny" noises as well although most of them shouldn't be repeated in respectable company - or on outers for that matter.

Thanks for the pics and links...... unfortunately I've got more crossmembers and they aren't in the same places as everyone else's so its custom all the way - as #$%^ usual.

And....... I'm not satisfied with the lack of ribbing or support with flat sheet guards. Even the vertical part of the strengthened standard guard is caved in and has bent the mounting bolts.

THis one is going to be STRUCTURAL.......

Its even better than first suspected... tore off the bottom and RHS rear lugs on the diff.

Thats 6 12mm HT bolts missing - no wonder it was a "bit" loose.


RHS Rear Mount or what's left....



Lower rear "mount"

Well it was even better ( or worse ).

Took a tooth off the crownwheel and damaged the inside CV. When the diff dropped the driveshaft must have rubbed on the outside edge of the inner CV cup and it burred over the circlip retaining groove making it impossible to simply remove the retaining clip and spider.

Ended up turning the end of the cup off in the lathe to get it apart as I needed to reuse the axle as its longer than stock and made of "dammexpensiveum"......

Thought I'd have to use a carbide tool but the cups are softer than expected - time for birfield rings