Axle Swap Question - Defender Source
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  #1  
Old July 30th, 2014, 08:12 PM
javelinadave
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Axle Swap Question

I'm trying to think everything thru before I lay a wrench on my truck. Here is what I have and what I am wanting to do.
Currently: 1986 ExMOD 90 with a 10 spline front axle with solid disc brakes
Wanting: Swap in a 24 spline axle off of a 96 Disco 1

I'm going to install new bearings, oil seals, disc rotors and pads onto the Disco axle before I install it. My question is will the currently being used calipers be usable or do I need to use calipers specific to the 96 Disco axle? I'm trying to get all the parts together so this stays a planned one day, one six pack, one pizza project.
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  #2  
Old July 30th, 2014, 08:16 PM
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Why? The newer axles have a weaker bearing setup and weaker CV joints. The 24 spline (stock) axles are the same strength as the 10 spline and the diff is not much better.

The Disco should have vented caliper, so won't swap. The 110 calipers will have bigger pistons (I think) so are better.

If you want a stronger axle, the better path is to replace the diff with an aftermarket 24 spline and the half shafts.
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  #3  
Old July 30th, 2014, 08:16 PM
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you can upgrade to defender calipers and vented rotors…

Sorry had to bail, still in clean-up mode
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  #4  
Old July 30th, 2014, 08:26 PM
javelinadave
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Quote:
Originally Posted by mongosd2 View Post
you can upgrade to defender calipers and vented rotors…

Sorry had to bail, still in clean-up mode
No worries. Lunch was good and It was nice meeting you and Mike in person.

Quote:
Originally Posted by JSBriggs View Post
The Disco Caliper has Metric holes for the bolts, the early 10 spline most likely has SAE. Keep in mind a fine threaded SAE bolt will physiaclly thread into the metric caliper mounts but it wont ever hold the torque. so you need to pull the bolts and match then to be sure, you cant just see if it goes in teh hole.

I guess what Im saying, you will need to redrill the holes in the old caliper to mount the metric bolts.

-Jeff
Thanks Jeff. I'm going with the hole size is pretty important so I'll swap in some new ones.
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  #5  
Old July 30th, 2014, 09:00 PM
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96 D1 is solid rotors not vented.
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  #6  
Old July 30th, 2014, 09:32 PM
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Will Tillery was offering two calipers, two vented rotors, and pads for like $338 shipped. 90 brakes are an upgrade for a disco 1.

http://www.discoweb.org/forums/showt...eferrerid=6565
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  #7  
Old July 30th, 2014, 09:43 PM
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When I put the Tru Trac in the front of my '87 110 I needed to go from 10 to 24 spline. I tried to use some Disco axels and CV's but I think the whole hub assembly is a different width from earlier Defenders to later Defender/Discos. Now as a disclamer, I have been out drinking Corona Lites with friends since happy hour. But I do rember it being a total shit show. Maybe Uncle Douglas will chime in because I texted him like 400 times about it and he even sent me a set of Disco axels that didn't work. My .02 cents.
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  #8  
Old July 30th, 2014, 09:44 PM
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My build uses the axles from my 95 D1. Has proven tough enough for 19 years
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I don't know about the brakes, only their unreliability.
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  #9  
Old July 30th, 2014, 09:50 PM
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The problem with using the disco axle is you need to replace the cv joint with aftermarket ones and change to better calipers as well as changing the diff and half shafts.

If you stay with the original axel you can keep the stock cv joints and brakes and only change the diff and half shafts.

The disco axle is a downgrade and needs much more money to make as strong.
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  #10  
Old July 30th, 2014, 09:57 PM
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Red90 is spot on. Installing a Discovery axle is a downgrade, not an upgrade. If your MOD 90 has the original axle in it, it's a HD 110 spec unit. The only thing you need to upgrade is a 24 spine diff and new inner axleshafts. Otherwise, you already have all of the parts that everybody else upgrades to.

Seriously, don't do it.
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  #11  
Old July 30th, 2014, 10:10 PM
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Just so you understand what we're talking about here. Left is 23 spline CV end inner axle (what you have now). Right is 32 spline CV end inner axle (what's in a Discovery)



24 spline diff/23 spline CV inner axleshafts from your favorite vendor, plus a 24 spline diff, and you have literally the strongest front axle assembly you can have using a Rover housing and all Rover pattern parts.

Another secret, your truck will have a 24 spline 4 pin open rear diff. This is very, very strong. You can install a locker in the rear, and move the 4 pin rear diff to the front for free. Then, for just the cost of new inner axle shafts, you have built yourself a very, very strong front axle.

By the way, if you do decide to go ahead with the cockamamie Discovery axle swap, you will need to change radius arms as well because they are a different width.
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  #12  
Old July 30th, 2014, 10:20 PM
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Yea, I think this is what I ended up doing. I called Bill at GBR.

Quote:
Originally Posted by transientmechanic View Post
24 spline diff/23 spline CV inner axleshafts from your favorite vendor, plus a 24 spline diff.
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  #13  
Old July 30th, 2014, 10:24 PM
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I am now way confused. Adam I just sent you a PM.
FWIW I cannibalized the radius arms with the axle.
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  #14  
Old July 30th, 2014, 10:29 PM
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Yes. Check if the rear is a 24 spine HD unit. They are quite strong. The shafts are much stronger than later model shafts and the diff is basically bulletproof. As stated it is a good swap to the front if you want a locker in the rear and an open front.
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  #15  
Old July 30th, 2014, 10:30 PM
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Quote:
Originally Posted by JSBriggs View Post
Adam is right. Some how I was thinking you were swapping out the rear. You have stronger axles in there.

-Jeff
The rear is a 24 spline out of a 97 D-90 and it's already installed.
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  #16  
Old July 30th, 2014, 11:43 PM
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Alright, I talked to JSBriggs on the phone and it looks like I'm better off with what I have already soooooooo lets look at what a good day yesterday was.
I ate a bacon sandwich for breakfast.
I drove from Phoenix to Tucson with JohnsD90 who was out here on vacation.
We met mongosd2 and Mike M.
We tore apart a Disco 1 and removed the front axle which John and I hauled home.
The 4 of us attempted to eat a fabulous Mexican lunch.
Frank had a flood at his house (that was not good) so he didn't get his lunch.
John and I went to an aircraft graveyard and I bought a 747 side window for $10.
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  #17  
Old July 31st, 2014, 09:40 AM
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Quote:
Originally Posted by javelinadave View Post
The rear is a 24 spline out of a 97 D-90 and it's already installed.
Did you keep the old axle? If it is the HD version, the diff and shafts have value.
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  #18  
Old July 31st, 2014, 10:05 AM
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Quote:
Originally Posted by Red90 View Post
Did you keep the old axle? If it is the HD version, the diff and shafts have value.
The old axle is sitting in my back yard.
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  #19  
Old July 31st, 2014, 10:11 AM
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Pull a half shaft and see if it is 24 spline at the diff.
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  #20  
Old July 31st, 2014, 10:15 AM
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Quote:
Originally Posted by transientmechanic View Post
Another secret, your truck will have a 24 spline 4 pin open rear diff.
Mine was 10 spline:

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