Author Topic: Perentie 4x4 front axle upgrade  (Read 490 times)

Offline Carzee

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Perentie 4x4 front axle upgrade
« on: June 26, 2019, 11:36:59 AM »
This issue has been mentioned in passing in a few different threads when an enquiry about diff locks or broken axles has come up.

I'd like to nail down the parts required for a future upgrade - I will be gradually collecting the parts needed for when my 10 spline front axle stuffs up. Just a matter of time.

As a start I have purchased a used Disco front diff (see pic below from seller).

"24 spline diff centre from a disco 2 front. It will fit rear of disco 2 and disco 1 and also front of disco 1 and defender."

I'm assuming this is the one that can fit the std Perentie 4x4 GS and FFR diff housing. Its costing $150 plus freight to find out :) Maybe could've taken time to shop locally but never mind..

Obviously the whole RFSV diff and front axle housing is stronger/beefier... but putting that to one side, the issue is mainly the differential and the axles. The CVs as well?
« Last Edit: July 31, 2019, 09:58:00 AM by Carzee »

Offline DennisM

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Re: Perentie 4x4 front axle upgrade to RFSV spec.
« Reply #1 on: June 26, 2019, 06:34:41 PM »
I had one (it came with my 110) I gave it away cheers dennis

Offline Carzee

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Re: Perentie 4x4 front axle upgrade to RFSV spec.
« Reply #2 on: June 27, 2019, 10:02:31 PM »
Hi Dennis, my CVs were different... non-matching types, not brands, and at a guess (probably) a result of a roadside RAEME temporary fix which never got replaced later on base. [Non-tech inspection pass, all good to go!]

Anyway, a couple of years ago we upgraded the CVs to the AEU2522 variant at the Series Workshop when the front end was inspected/serviced new swivel bearings etc.

edit

Turns out that we didn't fit the AEU2522 CVs from the 110 County model. We fitted RTC6862, the std CVs. (I don't know how I got the idea we had put in AEU2522s because the std Perentie half-shafts won't fit them).
 
The AEU2522 CVs are a match for the (aftermarket) HiTuff 24 spline (diff end) 23 spline (CV end) Maxidrive brand heat treated Chrome-Moly Steel front axle set.

Also, here is some info learnt when you offer up the Disco diff. There is a stud hassle.

The Disco diff ratio is right, the stud pattern is right, but the Disco diff mount (where the studs go through) is the same thickness the whole way around. Problem: the (removed) original Perentie diff carrier casing has an area of thick casing and an area of thin casing. The corresponding std Perentie axle housing/diff housing has the circle of about 10 studs protruding from it. Most of the std Perentie diff carrier is the same thickness as the Disco but it also has a thinner section involving 4 of the mounting studs from the axle/diff housing. So we need to change out the 4 x "R561195" short UNF 3/8in wheel studs and fit 4 x "R561196" UNF 3/8in, 1 inch and 1/8in long studs (RPS section KA describes the studs as wheel studs). 

I have noted whilst looking at Maxidrive HiTuff axle suppliers that it also entails using the Maxidrive Flanges and mandatory to unfit the standard Perentie front moly grease lube spec. and fit (revert) to the liquid oil swivel/flange lube spec.

Parts List:

4 pinion - 24 spline diff 3.54:1 (FTC782) with 4in diameter 4 hole Prop Shaft Flange
4 longer R561196 studs for mounting the diff to the axle casing.
Maxidrive Hy Tuff Engineering brand Front Axle set (HTE2520/21.24), 24 spline diff end ~ 23 spline CV end
2 x CV units, (AEU2522) 23 spline
2 x Maxidrive HD Drive brand Flanges (MDE5806)
2 x Drive Flange Gaskets 0.4mm Defender 86>94 (FRC3988)
4 x Prop bolts and nuts (axle end)
2 x inner tab washers
2 x outer tab washers
Sealant at flange end

Only the axle end of the prop needs to be undone.
The diff was mounted using a sealant. No gasket reqd.
My bearings and seals were renewed repacked only 2 yrs ago.
« Last Edit: August 29, 2019, 09:09:49 AM by Carzee »

Offline 303Gunner

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Re: Perentie 4x4 front axle upgrade to RFSV spec.
« Reply #3 on: June 27, 2019, 11:00:02 PM »
Have you looked in "The Library"?

RPS2207 is for the RFSV and details the front differential components you're discussing in Sections KB and KE.

Section KE notes "Heavier shafts than normal 4x4", and lists CV's as FTC252, the same CV's used in the 6x6.

Offline Carzee

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Re: Perentie 4x4 front axle upgrade to RFSV spec.
« Reply #4 on: June 28, 2019, 05:48:46 PM »
Thanks for that info - I looked over that parts scale as you suggested, but none the wiser on spline counts though. Lacking hands on experience so..

It was smart of them to simply fit the RFSV with the heavier duty 6x6 parts. I could not check the SRV scale but it is likely the same.

The auctions have seen a number of u/s 4x4 and 6x6 front axle assemblies.  Some enthusiasts must've got the RFSV upgrade parts that way. It would be good to get some stories here.

Offline Carzee

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Re: Perentie 4x4 front axle upgrade to RFSV spec.
« Reply #5 on: July 27, 2019, 04:19:07 PM »
I have the front half-shafts (HTE2520/21.24) being shipped from Kingpin Design and Fabrication up in SEQ, and the HTE flanges also.

While I'm waiting I searched around on REMLR and AuLRO and made some relevant notes for reference.

Perentie (all variants) Front Half-Shaft notes via Richard Green:

"Following turndown of the earlier combination, axle shafts were sourced locally and after testing (both static &
dynamic), in concert with DoD, of all non genuine CV replacements, a suitable overseas manufactured CV was
selected."

Accordingly, the following replacement P/Ns apply to the variants listed by RPS.

Front Axle Shafts:
-----------
"Up to Front Axle Housing No. 20L48865"

RPS 02188, 02189, 02190, 02191, 02192, 02194, 02195

AEU2520 RH Half Shaft – CV end 23 Spline, Diff end 10 Spline - NLA* RAI** part number BYG4556

AEU2521 LH Half Shaft – CV end 23 Spline, Diff end 10 Spline - NLA* RAI** part number BYG4557

AEU2522 C.V. Joint – External Drive Flange end 24 Spline, Internal Half Shaft end 23 Spline - NLA* RAI** part number BYG4564


"From Front Axle Housing No. 20L48866"
(Progressively changed in-service on ‘as needs’ basis, but some remain unchanged)

RTC6754 RH Half Shaft – CV end 33 Spline, Diff end 10 Spline - NLA* RAI** part BYG4564 with BYG4556 with circlip and spacer from original AEU2520/AEU2522

RTC6755 LH Half Shaft – CV end 33 Spline, Diff end 10 Spline - NLA* RAI** part BYG4564 with BYG4557 with circlip and spacer from original AEU2521/AEU2522

RTC6862 C.V. Joint – External Drive Flange end 24 Spline, Internal Half Shaft end 33 Spline - NLA* RAI** part BYG4564 with BYG4556/BYG4557 and circlip and spacer from original AEU2520/AEU2521/AEU2522

-----------
RPS 02207/02290 (02227/02256)
-----------
Note: Some RFSV were upgraded (02290) and some were converted to SRV (02227) and subsequently SRV (SF) 02256.
However for mechanical parts, RPS 02207 still applies.

AYG7168 RH Half Shaft – CV end 23 Spline, Diff end 24 Spline – RAI**

AYG7169 LH Half Shaft – CV end 23 Spline, Diff end 24 Spline – RAI**

AEU2522 C.V. Joint – External Drive Flange end 24 Spline, Internal Half Shaft end 23 Spline - NLA* RAI** part BYG4564

-----------
RPS 02185, 02186 (02232), 02208, 02209, 02210 (02222), 02211, 02212 (02262/02263), 02219
-----------
AYG7225 RH Half Shaft – CV end 23 Spline, Diff end 24 Spline – RAI**

AYG7226 LH Half Shaft – CV end 23 Spline, Diff end 24 Spline – RAI**

AEU2522 C.V. Joint – External Drive Flange end 24 Spline, Internal Half Shaft end 23 Spline - NLA* RAI** part BYG4564

-----------
RPS 02225, 02226, 02228,
-----------
Note: Bushranger 6x6 variants utilized a metricated Differential, which, whilst components are not interchangeable with the earlier Perentie diff, is as an assembly completely interchangeable.
Accordingly differentials of both types will be found on both Perentie and Bushranger vehicles.
Both Diff types are two pinion H/Duty diffs.

AYG7225 RH Half Shaft – CV end 23 Spline, Diff end 24 Spline – RAI**

AYG7226 LH Half Shaft – CV end 23 Spline, Diff end 24 Spline – RAI**

AEU2522 C.V. Joint – External Drive Flange end 24 Spline, Internal Half Shaft end 23 Spline - NLA* RAI** part BYG4564

-----------
RPS 02227/02256
-----------
Note: Bushranger 4x4 variant/s (SRV) utilized a metricated Differential, which, whilst components are not interchangeable with the earlier Perentie RFSV diff, is as an assembly completely interchangeable.
Accordingly differentials of both types will be found on both Perentie and Bushranger vehicles.
Both Diff types are two pinion H/Duty diffs as opposed to the single pinion standard 4x4 diffs.

AYG7168 RH Half Shaft – CV end 23 Spline, Diff end 24 Spline – RAI**

AYG7169 LH Half Shaft – CV end 23 Spline, Diff end 24 Spline – RAI**

AEU2522 C.V. Joint – External Drive Flange end 24 Spline, Internal Half Shaft end 23 Spline - NLA* RAI** part BYG4564


“No single pinion Perentie production differential was ever anything other than 10 spline at the diff end”.


NLA* = No Longer Available UK part
RAI** = Replacement Australian Item


Flange notes:
LR flange part "FRC5806" (suit LHR LHF RHR RHF). The flange bolts torque setting in the manual is 65nm but some have been known to snap the head off at that setting, some have even snapped off undoing the bolt.

From Blknight on AuLRO - fit bolts with with sealant after you clean out the threads and the sealing faces. Inspect all bolts for stepping and stretching and chattering marks, replace if required or unsure. Loctite 243 sealant or Permatex "Ultra Blue" gasket maker and Permatex "Thread Locker Blue" (medium strength) recommended. Tighten to 20nm in a star pattern to seat everything, secure the circlip and check for some lateral free play of the axle in the drive flange. Tighten to 60nm in a star pattern and then recheck.

If you have a snapped flange bolt, drill it, tap it / Helicoil it with a m10 x 1.5mm kit.

EDIT.

Adding 2 more Notes.

1. Regarding the upgraded HTE Flange and their screw on axle caps. HTE say to go to approx. 60nm using a hub spanner and to avoid using thread locker. To prevent loosening due to vibrations HTE suggest Locktite 567 master pipe sealant is better as it can be undone without trouble if required.
2. HTE half shaft /axle upgrade also means that the Special Grease in the swivels is changed out - reverts to Oil in the swivels.



« Last Edit: July 31, 2019, 10:16:49 AM by Carzee »

Offline Carzee

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Re: Perentie 4x4 front axle upgrade
« Reply #6 on: July 31, 2019, 10:20:09 AM »
The axles and flanges have arrived... the swap is booked in (3 weeks wait).

Offline Carzee

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Re: Perentie 4x4 front axle upgrade
« Reply #7 on: August 29, 2019, 09:04:01 AM »
After more than my fair share of delays, I drove the FFR home a couple of days ago, all done. Ended up fitting a new stub axle on one side, an unexpected problem.

 Now to turn attention to the rear axle and diff....