Disc brake conversion issues... - Defender Source
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  #1  
Old June 19th, 2019, 02:35 PM
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ROGERS MASSON
62 Series iia 109 w/200tdi
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Disc brake conversion issues...

Quick edit in regards to Red90's reply below, don't think I was clear at the start of this post, apologies. ---In order to fit the disc brake conversion kit, the stub axles have to be series iia spec.

Converting my 62 Series iia 109 to front disc brakes. Purchased them from Rocky Mountain (Torrel) and have been in contact with Jeremy (who is kickass with info and help). Have run in to a strange issue/problem, and hopefully someone can shed some light.

This is the stub axle I pulled off my 109, it looks to be from a Series 3, post 1980(?). I'm a nube to all this, so forgive me for not seeing the obvious things.Click image for larger version

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It fits snugly up against the half-shaft.Click image for larger version

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Here is a new stub axle I purchased from Rovers North, it is the correct Series iia stub axle. But as you can see below, it does not fit snug as a bug up against the half-shaft.Click image for larger version

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Is this a problem? What am I missing here? Is there another bearing that sits between the half-shaft and the Series iia stub axle? A distance piece?

Here are two pics of my half shaft/front left shaft as well, if that helps.Click image for larger version

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  #2  
Old June 19th, 2019, 03:37 PM
LR Max
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Thomason, Max
1973 Series 3 109
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Looks like you've got a later front axle (80 and after) installed. I say this because the front axle stub is 24 spline, not 10 spline.

So you've got a late series 3 front axle and its all metric (I believe).
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  #3  
Old June 19th, 2019, 03:42 PM
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ROGERS MASSON
62 Series iia 109 w/200tdi
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Ah, I see. So, am I screwed on the ability to swap out the stub axles? Have to purchase new half-shafts? Thanks for the reply and info, Max!

------ Follow up post added June 19th, 2019 02:44 PM ------

Or, just a thought, could I have this one's collar machined down to match the iia stub axle?
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  #4  
Old June 19th, 2019, 03:52 PM
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Why are you wanting to change stub axles?
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  #5  
Old June 19th, 2019, 05:12 PM
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Hey John, thanks for the reply. Would rather not, but have to change them out to the proper series iia stub axles in order to fit the front brake conversion to disc brakes. The existing ones do not fit in to the hub as required for the conversion.
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  #6  
Old June 24th, 2019, 01:20 PM
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Quote:
Originally Posted by FRM View Post
Hey John, thanks for the reply. Would rather not, but have to change them out to the proper series iia stub axles in order to fit the front brake conversion to disc brakes. The existing ones do not fit in to the hub as required for the conversion.
I have never done this conversion but read somewhere (possible rover's north magazine) where the stubs needed to be machined, never understood why now I see the possible reason.
I sure someone has a solution to this quandary.
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  #7  
Old June 24th, 2019, 01:40 PM
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Quote:
Originally Posted by FRM View Post
Hey John, thanks for the reply. Would rather not, but have to change them out to the proper series iia stub axles in order to fit the front brake conversion to disc brakes. The existing ones do not fit in to the hub as required for the conversion.
Just talk to Rocky Mountain. They will have all of the answers.
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  #8  
Old June 24th, 2019, 07:30 PM
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Hey Red90, I did speak with Jeremy and he was absolute in his assurance of fitment specs. Solid dude and really knows his stuff. Series iia stub axle should be a easy and pain free fit. Here's what I've discovered though, as mentioned by carlosz above, it looks like I may have to have to have the stub axles machined(?). Hope not.

Don't suspect it's the conversion kit, as it seems to be really well engineered. Perhaps I have the wrong stub axles? Perhaps they are "correct" but were manufactured to the wrong specs? At a complete loss at this point. Have never given up on anything in my life, but this one has truly thrown me for a loop. Almost....almost took it all apart and just went back to the old drum brakes. Ugh. Really would like to figure this out though.

Here is what I have discovered re Series iia stub axle...

Just inboard of the threads- 41.53mm
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First shoulder- 46.17mm
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Second shoulder- 59.12
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If anyone who has a series iia stub axle, and has a moment, could help out and verify these measurements against their own stub axle, it would be greatly appreciated. And, I'll buy you a six pack of your favorite beer.

The bearings, which are series iia spec, that came with the brake kit measure...

Inner bearing/inner diameter- 45.56mm
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Outer bearing/inner diameter- 41.00mm
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These do not, at all, fit. The inner bearing alllllllmost gets on the first shoulder, just enough to cause the oil gasket to rip apart while trying to get the hub back off. The outer bearing wont even go past the threads on the stub axle.

Thoughts?
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  #9  
Old June 24th, 2019, 08:21 PM
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ROGERS MASSON
62 Series iia 109 w/200tdi
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Just had a thought....

Are the front and rear stub axles on a series iia different in size or design?
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