Outer Limits 4x4 Board

ok so i hav done a quick search through the forum but cant find any good info/pics on home made rear disconnects. i have a hilux that i have built for comps and as many would know the turning circle is s@!$t house i have seen the already made ones both yuri and trail tough but as with everything else on the lux im a tight arse and if i can make it i will. id really appreciate it if some one can post some pics of theirs or point me in the right direction of a thread or web page thats got a good build up of one.
thanks brendon

Here is mine I made for my lux. Used some gears from a 40 series transfer.














Cheers
Aaron

[quote="uglystik01"] but as with everything else on the lux im a tight arse and if i can make it i will.

Thats funny!
But on a serious note , Aarons works very well and it didn't cost much just a bit of time and effort.
Mick

thanks for the pics i understand the basics but how did you have the output shaft and the flange split while being supported.

I machined an output flange down and welded the fatter gear to it. This becomes the drive unit. The other piece is machined shaft that has a female thread to suit the transfer output shaft (20 x 1.5mm). Then the other gear is welded onto a machined flange unit that takes 2 bearings and is bolted onto the made shaft which holds the bearings and flange on. I used the fork that came out of the 40 series transfer and hooked it up the an air cylinder (25mm x 12mm stroke) perfect fit. It's all operated by a flick of a switch.

There is a bit of internal machining of the gears themselves which makes it a little harder to do. I would suggest putting them in the oven on high and letting cool down slowly. I didn't do this but I should have. I did to weld them though so the welds didn't crack.

I will pull it off my truck after this weekend and take more pics and measurements for all who wants to have a go. Don't want to make any more.....

Hope this all makes sense.........

thanks for that pics would be great

After buying and stripping down a 40 series transfer case and gearbox, I found out that I used the gears out of the Gearbox NOT transfer case. All the ones are flogged out in the transfer.

This one is slightly different from the first set I used but will turn out the same.

Will get some pics and measurments this time when I make it.

Have to get my lux back so I can strip the one in the car to copy.

Keep ya guys updated.

This new one will be in the 4 sale section if it turns out. So keep an eye out.

Here's a link to another post. Sloshy made his out of hilux transfer parts. He has strip down pics.

http://www.outerlimits4x4.com/viewtopic ... 8&t=213529" onclick="window.open(this.href);return false;

thanks for that now ive just gotta pull my finger out and make it

Disconnect is comming along sweet. Most of the machining is done. This one is totally different to the last design. This one will only end up 30mm longer than the normal output flange. Cut down heaps of weight to put less strain on the output bearings of the transfer.

A few things to check but should have pics up over the next few days.

Then weld it up and a little more machining.

Need to make up stub shaft, weld on the flange and make a spacer ring for the tail shaft locator. Got to check to make sure the flange I'm using is a rear one, otherwise I'll make a new one. But here are some pics. Enjoy!

Have to change the bearing hub design again. Put the setup on my spare transfer and only having the bearing hub at 30mm isn't going to work. The hub will have to be around the 50mm mark which is what my first one was. This way I will fit 2 bearings and a bigger stub shaft.

Nearly finnished. Ended up only about 44mm long. Can't beleave how much work there is in making these. Don't know if I'l do another.

Just got to drill the holes for the tailshaft bolts.

thanks for all the pics and everything this will be pushed to the back of the wish list at the moment i gotta sort out my engine and box. decided to do a v6 conversion as i will be setting the lux up as a winch truck and ill be building an lj50 into a rockcrawler

Just welding the air ram brackets on tonight and it will be finished. This one is a complete bolt on setup with an air ram to activate. Keep an eye for it in the for sale section.

Willy Hilux wrote:Just welding the air ram brackets on tonight and it will be finished. This one is a complete bolt on setup with an air ram to activate. Keep an eye for it in the for sale section.

use the slide dog of a 60s landcruiser and a maxi-drive range rover diff lock actuator. the 2 will bolt together on a 40s front output housing mated to the rear hilux housing, over all it is about 3 inch longer than the standard hilux and you can still use the standard speedo drive.
If you have a twin stick, you can fit an SR5 gear knob with shift on the fly button to one of the sticks and use the button to engage or disengage the rear.

NICK

Does the 40s output just bolt to the hilux output. I'll have to look at this as I have a 40s case at home. Interesting tech. I'd like to see this done.

no it doesnt. I slotted it over the top and welded around it.

whats your email, ill send you some pics to post.

PICS........

More Pics....

Made a new one using Hilux transfer gears. Made from single piece solid steel. ended up being 50mm long due to the fact that the gears were smaller. Should be heaps strong enough as they are in ya box anyway and never heard of them breaking. Will get pics up soon.

Using larger gears I think I should be able to get them down to 35mm long + about 1-2mm gap between gears . Would be good to get these into production, , but the gears would be hard to come by at a cheap rate.

Thanks for posting those pics!
Good stuff

One using gears from hilux transfer.....

did you get the email I sent you? what did you think?

Looks good. But Would be a pain to make up. Thinking outside he box though.

Here is a basic pic if any one want the low down on making one up for any 4x4 using it to bolt onto the existing output flange.

Good luck....

For those that are interested, here is the breakdown off the "Trail Tough" Rear Disconnect.

http://pirate4x4.com/forum/showthread.p ... rive+shaft" onclick="window.open(this.href);return false;