Outer Limits 4x4 Board

I picked up a set of 30/30 longfields and other bits when I was in the US recently (thanks to Keith from Rovertracks). And since it will be a year or so since I put them in the IIA (I am in Germany, the IIA is in OZ), I thought I would post some specs for those interested in them and when I get around to it do a hardness test and some machining on them. Will post some pics soon too.

Specs:

Shaft and shaft splines
Shaft diameter 32.5mm (non waisted)
Minor spline diameter 30.8mm
Major spline diameter 32.5mm
Pressure angle 45°
Length of splines at full depth 42.5mm
Depth of threaded bolt hole in CV 24.9mm

Bell
Bell outer diameter 90mm (anyone have an AEU2522 they can measure to compare?)
Bell outer diameter across flats 85.7mm
Bell inner diameter 64.8mm
Bell diameter balltrack-balltrack at rear 73.3mm
Depth of bell cavity 55.4mm
Ball diameter 17.4mm (difficult to measure exactly)

Star splines (female)
Major diameter 33.1mm (deeper V to cut than splines on shaft - shaft splines have rounded roots)
Minor diameter 31.1mm
Length of splines 25mm (c-clip groove in middle of splines (obsolete))
Pressure angle 45°

So does anyone hane an AEU2522 handy that they can measure the bell dimensions to compare? I will be machining the stubs on these CV's down below the major spline diameter so that I can minimise the amount that the stub axles need to be bored - the stubs then only need to be bored to a very slight press-fit with the splines (32.5mm). The bell and shaft of the CV is through hardened 4340 so machining the stub shaft slightly smaller shouldn't weaken the CV.[/b]

Interesting to note the cut of the splines in the first pic - the splines get longer as they go around the CV - this is the same on both CV's.

The pics after machining are added at the end.

I've got an AEU2522 that failed on the stub shaft. i can measure it and PM you the dims later this week.

ISUZUROVER wrote:I picked up a set of 30/30 longfields and other bits when I was in the US recently (thanks to Keith from Rovertracks).

Snip ...

Star splines (female)
Major diameter 33.1mm (deeper V to cut than splines on shaft - shaft splines have rounded roots)
Minor diameter 31.1mm
Length of splines 25mm (c-clip groove in middle of splines (obsolete))
Pressure angle 45°

Snip ...

Ben,

Why do you say this c-clip groove is obsolete?

I thought it was a brilliant solution, using this c-clip to locate the axle in both axial directions. Thus avoiding the need for a stress raising step in the axle at a critical location and a martack at the inner end.

Bush65 wrote:
Ben,

Why do you say this c-clip groove is obsolete?

I thought it was a brilliant solution, using this c-clip to locate the axle in both axial directions. Thus avoiding the need for a stress raising step in the axle at a critical location and a martack at the inner end.

It max be a brilliant idea, but I was told by Keith (from rovertracks) when I picked up the longfields that Bobby Long isn't using it anymore with his axles, and neither is keith with his rover and toy conversion axles. I can't remember the exact reason why, you would have to email them for more info.

And while on the subject of c-clips, two c-clips were supplied with the longfields (I assume for the outer stubs). These 2 c-clips are basically bent bits of wire, and are all but useless. It is funny that such poor quality c-clips are supplied with what is otherwise a high quality component.

The groove was taken out at it was breaking regularly in the 27 spliners

DiscoDino wrote:The groove was taken out at it was breaking regularly in the 27 spliners

You mean the axles or the star? It better not be the star because my stars have the groove in the middle.

Interesting info from a big test of CV's and axles in the US. The newfields are apparently now being made as a direct replacement for the LR AEU2522 and the volvo C303 CV.

Interesting that the Longfield 30/30 CV (in bold) appears to be stronger than a stock D60 front axle. All the longfield/newfield CV's broke the inner axle before the CV failed!!!

................................................ft lbs * degree * inner axle used * failure

stock toy birf..............................3700 .....30........long 4340.......birf expolded
randys birf elimn kit......................5000.....40........randys ...........ujoint broke
long treated oem birf....................5100 .....45.......long 4340.......stub broke
newfield 4340 birf........................7000......80.......300 m.............inner axle broke
longfield 4340 birf........................7000......80.......300 m.............inner axle broke
longfield 30 spline birf...................8900.....120......4340..... .........inner axle broke

stock toy 27 spline inner axle..........4000....20.......................... ..axle broke
stock dana 44 30 spline inner..........5200....25......................... ...ears broke
pig toy 27 spline 4340 inner............5500....90....................... .....axle broke
yukon dana 44 30 spline 4340 inner..5800....48............................yoke broke
longfield toy 27 spline 4340 inner.....6500....80............................ax le broke



stock dana 60 35 spline stub..........8300......80 ..........................ears broke
yukon dana 60 35 spline 4340 stub..12000....90..........................shaft broke

http://www.pirate4x4.com/forum/showthre ... ge=2&pp=25

http://www.pirate4x4.com/forum/showthread.php?t=351141

I thought the Newfields (CV Unlimited) were made to fit the newer, narrow hubs, not the AEU2522 wide hubs. These have been around for awhile.

red90 wrote:I thought the Newfields (CV Unlimited) were made to fit the newer, narrow hubs, not the AEU2522 wide hubs. These have been around for awhile.

You may be right, I didn't thoroughly investigate. I have asked the question on pirate. The kit is a lot of $$$ (about $1800AUD for 2 CV's and 2 inner axles).

RUFF wrote:http://www.pirate4x4.com/forum/showthread.php?t=352585

Thanks RUFF.

I'm running a stock suzuki 4 bagner 1.6L, spooled 5.29's, dual tc and hydro steering on 38.5 Boggers.

Posted by Bobby Longfield
We don't believe steering stops or tire size was a factor in this case. This is the very first cage we've seen fail. We don't know if maybe the inner axle by chance went past the snapring groove and ground in the bottom of the birf? :confused: Of couse we'll know alot more when we get a chance to look at it. we know anything breaks! And there is people running them with 42's with no breakage yet.

ISUZUROVER wrote:

RUFF wrote:http://www.pirate4x4.com/forum/showthread.php?t=352585

Thanks RUFF.

I'm running a stock suzuki 4 bagner 1.6L, spooled 5.29's, dual tc and hydro steering on 38.5 Boggers.

Posted by Bobby Longfield
We don't believe steering stops or tire size was a factor in this case. This is the very first cage we've seen fail. We don't know if maybe the inner axle by chance went past the snapring groove and ground in the bottom of the birf? :confused: Of couse we'll know alot more when we get a chance to look at it. we know anything breaks! And there is people running them with 42's with no breakage yet.

According to Bobby long, the balls, star and inside of the cage were rusty when he pulled the CV apart. And the rig had a welded front, which is extremely hard on the CV's. Hwever, this is the first recorded failure, will be interesting to see how many more occur.

Pics of the new long before machining added to the first post.

I machined the stub of the long slightly so that I will only need to machine out the rover stub axle to be a slight press-fit with the spline diameter of the longfield. New diamater is 31.9mm, outer spline diameter is 32.5mm.