Front and Rear Axle swaps in Ernest's gen1

[PajEvo]

@Whatthesheesh was kind enough to share pics with us of the process of swapping axles in his gen1, "The Goat". Here's what I have from him so far, and I'm hoping he'll chime in with tips, tricks, and answer questions for us...

The Goat.
Sweet little Gen 1v6 SWB with auto trans and Mark's 4wd 2.85 transfer case gears.
Swapped in 9.5" rear axle with Mitsu air locker and an ARB locker in the 8" low pinion front axle.
Pretty new 33x12.50r15 BFG KM2's.

Not mine, but came to me for, you guessed it.....
5.29 gear swap!

Here's some picks showing the process.
I'm not good at write-ups but I'll try to answer some general questions you may have.

This is not for the faint of heart.
I've spent a significant amount of money on the correct tools and I've done about 6 sets of these now so I feel pretty confident that I'm getting it right finally, lol!

Front diff getting ready for disassembly.
I have the ARB diff spreader, makes coming apart and going together easy

The goods. Front and rear Gear set from Fourgreen.com.
Heard they are not available through then.Right now.
Try to get part numbers on here.

The Hyundai ring gear used for the 8 inch front axle takes 12 mm Bolts versus the stock Mitsubishi 10mm. Got to drill to make the ring gear mate properly to the carrier, which also makes for No Going Back this becomes a dedicated 5.29 carrier

[PajEvo]

Lightly filing in deburring the edges from drilling so the ring gear lays flat on the carrier

Installing new carrier bearings

This tool is money! It's used for removing carrier bearings and pinion bearings. And saves a lot of time especially when you have to adjust shims and remove and install these bearings sometimes multiple times.

[PajEvo]

Pressing on an inner pinion bearing, these things go on very tightly.

New outer pinion bearing race installed in the housing

Just a snapshot of what this looks like when I'm In the Heat of the battle. I know it looks disorganized but I know where everything is and everything is kept very clean during the whole process.

This truck had a hundred mm CV on the passenger side but only a 95 mm CV on the driver side. In an attempt to find a hundred mm driver side CV axle I first tried to CVS out of age into Sr. That's about an inch too long and as you can see here won't allow the front end to go together. You need a CV axle out of a gen 1 V6 5-speed truck. That is the only thing that I'm aware of that is the correct length and comes in 100 mm diameter CV that fits this little truck

[PajEvo]

Gen 1 C V Next to Gen 2 cV

The CV joints have the size stamped into the outside of the Bell, this one is 95 mm as you can see by the markings

A little trick I've come to use when removing the third member from the rear axle get a chain wrap it around the pinion and use a come along to gently provide slow consistent outward Force. This allows you to remove the third member without beating the crap out of it with a hammer and to keep everything under control and from getting marred

9.5 inch ring gear Top 9 inch ring gear bottom. Although it looks quite a bit smaller, these 9-inch gears are really tough and I'm taking everything I can throw at them with low range transfer case gears and 37 inch tires.

[PajEvo]

The 9.5 in locker carrier with a 9 inch ring gear installed, see you still looks pretty beefy.

9.5 inch pinion on the left and the 9-inch pinion on the right

9 inch pinion has to be shimmed pretty deep in order to mate properly with a 9 inch ring gear on a 9.5 inch carrier

Pressing in the inner pinion bearing race in the 9.5 in third member

[PajEvo]

You have to use a 9-inch pinion flange when doing this because the 9.5 in pinion flange is a larger-diameter and does not fit on the 9-inch pinion

Ordered a CD from a gen one supposedly with a V6 in a manual trans and got this 25 spline 95 mm unit which obviously came from a 4-cylinder truck even though the wrecking yard denied it

Using a 9-inch pinion flange means you need to use a 9-inch pinion yoke or Driveline yoke to mate the proper bolt pattern on the 9-inch pinion flange

A simple trick to drive on the new pinion seal with the pinion installed is to use the big 9.5 in pinion flange flipped and then beat the pinion seal in nice and flush

A great trick for popping the axle loose from the housing is to take a 4 by 4 and pray against the end of it against the control arm trailing arm bracket tree

[PajEvo]

Pattern and backlash set up time to tighten everything down and install it!

[Crumb]

 Wow! Thanks for porting this over Phil. Great resource.

[Whatthesheesh]

Much of the credit for this needs to go to Lordtrunks and PA_JERO.
They did the research and took a gamble on some parts that "should work together".
Well, luckily they did!
And now we have the recipe for 5.29 gears in our Gen 1 and Gen 2-2.5s that is legit and proven!

[PA_JERO]

I'm so glad you guys like typing and posting pictures. I need to become more motivated at life. Nice work dudes.

[Landraider]

I'm not able to see the pictures here...   Sure wish I could see the amazing work being done. 

[IncorpoRatedX]

Months ago there was a server attack by spam hackers, it corrupted our attachments and we lost most of them. sadly, this thread was hit.

A moment of silence for the dead threads. RIP, until someday, someone, hopefully, revives them.

[Landraider]

 

If one could only get ahold of those folks.   

[Crumb]

 Phil might be able to revive this thread BUT i'm pretty sure the 5.29 tech is gone, don't think Ernest will be doing any more. So the few guys that got them installed into 9.5" rears are lucky and the rest are on their own. They go right in the 9" so there's that.

[Scottiebake]

Hi guys does anyone have the part numbers for the Hyundai ring and pinion used in this conversion looking at doing it myself any information would be much appreciated cheers.