Outer Limits 4x4 Board

Hoping someone might be able to tell me whether or not a 60 series rear drum assembly (the ones with the integrated handbrake) will bolt straight up to a 40 series diff assuming that I can get the full assembly and backing plate . . . appreciate that I'll need to source or fabricate the handbrake cable.

from memory, no, the backing palte holes are different, but you can re-drill them to suit. Me thinks the 60 has an odd shape to it, sort of traigular....We did the same on a 40, and after re-drilling the backing plate holes, it worked fine.

might i suggest just using a 60 diff??
throw one in the front now too. they are getting so cheap and you get extra width also??

DIRTY ROCK STAR wrote:might i suggest just using a 60 diff??
throw one in the front now too. they are getting so cheap and you get extra width also??

We did consider that option but the rig is just being put back together so it can be sold and we really can't justify spending any more than we have to on it. If we were keeping it, we would certainly go down that route.

I was hoping that if they would fit, that I might be able to find someone who has used some 60 series diffs for a buggy build, done an 80 series knuckle swap and moved the old 60 series disks to the rear and would be otherwise throwing out the old drum assemblies and backing plates . . .

Butt Craic wrote:

DIRTY ROCK STAR wrote:might i suggest just using a 60 diff??
throw one in the front now too. they are getting so cheap and you get extra width also??

We did consider that option but the rig is just being put back together so it can be sold and we really can't justify spending any more than we have to on it. If we were keeping it, we would certainly go down that route.

I was hoping that if they would fit, that I might be able to find someone who has used some 60 series diffs for a buggy build, done an 80 series knuckle swap and moved the old 60 series disks to the rear and would be otherwise throwing out the old drum assemblies and backing plates . . .

DAMN you put alot of thought into that one huh....
goodluck, put the old rear drums on it and flog it off then?

Yes, I have done it. You will have to drill the 60 backing plates to pick up 4 of the original holes on the 40 diff flange (top and bottom). The centre holes will line up. You will also have to grind back the flange around the top and sides to allow the 60 backing plates to seat properly (this is very important). A bit of mucking around but it can be done. The hardest part will be the cable. I used the 60 handbrake cable that I fabbed brackets for. Also fabbed up a joiner for the 60 cable to join the 40 cable with facility for adjustment.

Hope this helps.

Ray

DIRTY ROCK STAR wrote: DAMN you put alot of thought into that one huh....
goodluck, put the old rear drums on it and flog it off then?

I know of at least 3 people who have had buggy diffs built this way . . . . unfortunately all the parts that I am after were all introduced to the hopper.

The old drums are still on it. We got a 60 series gearbox and t/c to replace a cracked case and sus gearbox that was in it but unfotunately it doesn't run the handbrake on the output shaft. The gearbox is in already and I'm just looking for an easy (and cheap ) way out from here.

Bolt the hand brake drum to the rear of the transmission and shorten the rear propshaft....?

Sixty wrote:Bolt the hand brake drum to the rear of the transmission and shorten the rear propshaft....?

Wont work without modifying/removing the crossmember thats welded between the chassis rails. 60 box/transfer just clears it as it is.

Yes 60 series backing plates will fit straight on if your 40 series is built after 1980 no drilling required also use a HZJ79 handbrake cable if yours is a ute ot troopy (ps some HJ47's have a 6 bolt backing plate so this conversion can't be done to this type unless you change the complete diff).
BJ42 short heel base have hand brake on the rear also (same parts as 60 series except cable) so you can use the complete set up off of one of them if yours is a shorty built after 1980.

hope this helps!