Swapping D1 Axle into a D90 - Defender Source
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  #1  
Old June 11th, 2016, 09:38 AM
jashof
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Jason Hoffman
1986 90, RHD 200TDI
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Swapping D1 Axle into a D90

Got a good deal one a complete set of D1 axles with new brakes, rotors and a recent hub seal and bearing job. West coast, no rust.

The patient is a 1986 ROW RHD D90 and I was considering swapping in the rears when the drive shaft upgrade and RTE suspension next week. Right now it has drums in back and the new axles have discs. Anything else, eg proportioning valve, that would need to be done if I switched over to the newer rear axle? Any other considerations in doing this swap, from anyone who has done it or considered it?

Thanks!
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  #2  
Old June 11th, 2016, 10:06 AM
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Doug Crowther
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did you get the front radius arms with the axle ? If not you will have a problem, the 90 used a narrow arm and the disco used the later wide type (longer bushings with more surface area last longer/considered an upgrade).
The narrow arms shouldnt be used on an axle deisgned for the wider type but some here have done it using the Robert Davis effect
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  #3  
Old June 11th, 2016, 10:21 AM
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John B.
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There are some downgrades with going this way that should be understood. They can be addressed, but it is good to know.

- The wider radius arms reduce front articulation a fair amount.
- They have a narrower hub bearing spacing which is not as robust.
- The front halfshafts at the CV joints are very small. 67% the strength of what you have now. If you off road, these are a must upgrade...
- The front calipers use a smaller piston, so braking is worse. Good idea to change to Defender cailpers.
- The hub sealing arrangement is not as good and it is a good idea to change to the earlier hub seals and delete a few of the intermediate seals.
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  #4  
Old June 11th, 2016, 10:51 AM
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Sam
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Wouldn't an 86 have 10 spline half shafts at the diff? If so, you're upgrading to 27 spline with a disco axle.
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Old June 11th, 2016, 10:59 AM
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Jason Hoffman
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The d1 axles came with the radius arms
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Old June 11th, 2016, 11:11 AM
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good to go, the proportioning valve would be a nice touch but many just roll with the axle swap.
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Old June 19th, 2016, 11:46 PM
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Jason Hoffman
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Thanks for all of the great input. I've decided to just use the rears for now. One thing I just thought of is I'm wondering if my '86 90 has the same number of flange bolts in the propshaft as the 1997 D1 axle has on its flange. I'm out of town right now so I can't even check. Anyone know?
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  #8  
Old June 19th, 2016, 11:53 PM
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Quote:
Originally Posted by One Ten View Post
Wouldn't an 86 have 10 spline half shafts at the diff? If so, you're upgrading to 27 spline with a disco axle.
Yes but they are very small at the CV, much smaller than 10 spline. The earlier axles are better all around.

Also the late model 24 spline shafts are the same size as the 10 spline shafts.
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Old June 19th, 2016, 11:55 PM
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Quote:
Originally Posted by jashof View Post
Thanks for all of the great input. I've decided to just use the rears for now. One thing I just thought of is I'm wondering if my '86 90 has the same number of flange bolts in the propshaft as the 1997 D1 axle has on its flange. I'm out of town right now so I can't even check. Anyone know?
A D1 rear has a different flange for a Roto-flex. It needs to be changed for a u-joint flange.
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Old June 20th, 2016, 04:03 AM
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Thiemo Ebersberger
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Built a 110 pick up out left over parts in the work shop. 110 chassis and body, Rangie 4 speed box, 300 Tdi ex Disco and both axles off a 300 Disco. Left the axles untouched only cut the trailing arms to size in with.
Used the brake master and servo unit of the 110 300Tdi combined with the original Disco brakes. Works absolutely fantastic. The brakes are far more responsive and sharper than anything LR has ever built. This is our work horse runaround. Heavily loaded on very bad roads here in Kenya. Lots of towing work pulling Land Rovers on a straight bar. So the pick up has to to all the braking. Been going strong for 4 years now. Only the clutch gave in once.
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  #11  
Old June 20th, 2016, 04:42 AM
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Thiemo Ebersberger
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Disco axles, 4 speed Range Rover box, 300 Tdi, Chassis 200 Tdi
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  #12  
Old June 24th, 2016, 11:47 PM
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Jason Hoffman
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Quote:
Originally Posted by Red90 View Post
A D1 rear has a different flange for a Roto-flex. It needs to be changed for a u-joint flange.
Where can I get the U-Joint Flange? Can I just take the one off of my D90 rear?
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  #13  
Old June 25th, 2016, 12:32 AM
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Most likely it will be a 4 spline, but pull it first and check as you never know the history of these trucks. Flanges are easy to get either way.

Is the truck ex-MOD?
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Old June 25th, 2016, 10:42 AM
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Paul Kennington
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FWIW, I kept my rear diff & swapped it into the D1 housing. So I didn't have to deal with the rear driveline issue.
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  #15  
Old June 25th, 2016, 02:27 PM
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Quote:
Originally Posted by Red90 View Post
A D1 rear has a different flange for a Roto-flex. It needs to be changed for a u-joint flange.
Late NAS D1 have u-joints in the rear. I think 1998 and 1999. My 1996 D1 had a roto-flex, but the 1999 axle I put in my 90 came from a disco that had u-joints had u-joints.
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