Outer Limits 4x4 Board

I have spent hours running through endless threads brought up by the search engine while fishing for info, but have hit the wall

As we all know, it can be done, and there are a lot of people running them with good results.

I have found the step by step of how to build it, and its straight forward.

I have gone as far bolting it all together into the 3rd member, and that is where I have hit the problem.

I have used:

Front high pinion 3rd member and bearing caps

Rear LSD Carrier and bearings including shells

Front crown wheel and pinion


According to all of the info I have found so far, you just bolt it all together,
adjust the lash and pre-load and your away.

No so in my case, so there must be some tricks, or some tech thats been missed from the other threads.

The problems I have encountered are:

The front crown wheel will not pull down onto the rear carrier by VERY approximately a 1mm.

The carrier has to sit off set to one side a lot to get it to mesh with the pinion properly and not jam, as the flange that the crown wheel bolts to on the rear LSD carrier is a lot thicker than the front carrier.

The offset carrier binds on the bearing cap


What did you ACTUALLY have to do to get it to work??

To me, it looks like I might need to machine something off the inside face of the crown wheel to get it to pull down flat against the LSD carrier flange, then shim the pinion back about 4mm so I can centralise the carrier better.

I realise its hard to give answers on this sorta thing if you don't have the diff there in front of you, so I'm just curious to what extent others have had to play with theirs to get it to work.

I'll try and get some pic's

Did you have to machine the crown wheel??

Did you have to rest the pinion??

Did you have to do any clearancing on the housing??


Thanks,
Pete

As said via PM, the only thing we have done is machined the crownwheel (only a little chamfer, not the whole thing).

We haven't touched the pinion at all, just left it.
Took the open centre out, removed the crownwheel(then machined it) and popped it onto the rear LSD centre, fitted it into the front third member, set backlash and that was it.

Then obviously moved the filler up....