Since I posted above I've been in the shed starting on this.

First up cleaned up one of the other centres.

Then put the front end on jack stands and removed the wheels.

Then removed the left hub, caliper and rotor.

Then removed the right hub and caliper.

But then while looking at the inner right axle shaft it did not look right.

So compared it with the one on the open centre and it's obvious that it's not in the diff far enough.

I pushed the axle and it slid in another 50mm.

Put the hub back on and tried it. All worked as it should. So put the left back on and likewise everything is rotating as it should, just like an open diff.

So the problem appears to be that when I put the axle on i had not pushed the inner right shaft completely in.

However my thought now is that what's to stop it from moving out again. The open diff has a circlip that stops this shaft from sliding out of engagement with the side gear spline but there does not appear to be anything with the locker the shaft can be completely removed.

Mind you I've done about 30000k's with it like this and no issue, at least 20000k's have been with 4wd engaged (both 4hi and 4lo).

I've emailed ARB so I'll see if they answer before I pull it totally apart again.

 

Solved this.

Finally found an installation manual for the air locker here why arb does not have them on their site I don't know.

Now I just need to find a suitable spring, I'm sure I have some old valve springs somewhere.

The spring is inserted in the female spline of the inner axle shaft and when the outer axle shaft is inserted this applies pressure on the inner axle to hold it in the diff.

If your looking for an ARB locker for your Dana 44 IFS then it's an RD-117 for 3.73 and down gears.

 

Stripped splines on one axle or hub?

 

No.

Just not assembled completely.

All ok now.

 

Glad to hear you found/solved the problem.

 

Took Effii into town for the exhaust tail pipe to be made up and installed. First time on the road for up to 100kph. I'd run up to the end of our road a couple of times to bed in the brakes and make sure everything was working.

So first impressions is this diesel engine is great.

A corner on the way to town where I have to change down to second in the Mav and with the cleveland in Effii. 4th gear 40Kph to 80kph no problems.

So the exhaust is complete.

Modifying the tray.



Fitted the tray

 

So this week was supposed to be:

"Replaced the wheels and tyres with a spare set of 33x12.5R15 Goodyear Wrangler MT/R's.

Took the BFG all terrains off the 6 wheels and the wheels are at the sand blasters, should be back next week.

The BFG's will go on the Maverick and the newer MTR's (<10000 kms) on the Maverick will go on Effii."

But disaster.





Driving up to my mates place to change over the wheels we had a wheel come off, at 100kph, on a wet road, on a bend. Fortunately it was a rear wheel and it just dropped onto the drum backing plate.

So how did it happen. The back wheels have not been off for at least six months. My normal way of fitting them is rattle gun set to 60ftlbs and then when it's back on the ground torque wrench to 90ftlbs. So I don't know why the nuts came undone unless I'd forgotten to torque them after putting the wheel back on.

Found the tyre and wheel, wheel's stuffed (stud holes are thrashed out) but at least I'll be able to use the tyre.

So we get a tow truck and head home.



So here it is what happens when you lose a wheel.

I've now got to do a complete rebuild of this brake only things salvagable are the wheel cylinder, handbrake lever, some of the springs. Everything else is damaged or missing. One wheel stud is slightly bent, but I'll be replacing all of them.

Fortunately I've got another backing plate.

So some other things will be getting done while I wait for the rest of the parts.

Fitted the bunny burners.



These are IPF 9000's with 100w hid h3 globes installed.

I'll post some pics of them on when we get a night with no rain.

Completed all the breathers, diff's, transfer case, fuel tanks. Breather filters are up on the head board with 8mm PU tube to them.

 

Geez Ross, that could have been a lot worse!

Glad you're OK

 

Thanks, it's still quite a heart starter especially for the passenger.

 

Ouch Ross!

Don't know what sort of wheel nuts you had on
One of my old F trucks was a pig for wheel nuts coming loose
It was recommended I try ones simular to these






It solved my problem

Cheers,
Patchy

 

Thanks.

They look similar to the ones I already have.

Fully enclosed long enough to engage the full thread.

 

Think I'll go and check my 32 wheel nuts right now!
Unlucky to have happened, lucky it was not worse.

Easy mistake, I've done it one in a car many years ago & got away with it. Once my wife came back from a Landrover dealer service and complained to me that she could hear rattling when driving. I checked the wheel nuts, RH front were on finger tight. Blasted those guys who were apologetic & never went back. That's the worst thing about being your own mechanic. You can't sack yourself if you stuff up ! Well not easily anyway...

 

Ordered parts to fix the damaged brake.

More work on the tray. Set up the fuel fillers and modified the tie rail so they are easier to access.

Started cleaning all the oxidisation of the tray prior to putting a coat of alupolish on to protect it.

Put the spare set of Goodyear Wrangler MT/R's on. These are 33x12.5R15 and look good.

 

Replacement parts turned up for the brake so rebuilt it.

Installed the compressor, air tank and one of the auxillary batteries on the tray. These will be enclosed with the spare tyres once they are setup.

Installed the last of the interior trim.

Installed the centre console.




That's about it for the rebuild. Aside from being away for most of the next 4-5 weeks there is only a few minor things left to do:

Install the vehicle PC and screen, I'm doing a rebuild of the PC first to make it all solid state, all the music and maps are on this.

Connect the AC compressor, I'm waiting on the local AC guy to provide a fitting to go on the compressor that the hoses connect to.

Install the windscreen trim. Still cleaning and polishing these.

Install the flexiflares on the front, need these as the 33x12.5R15 tyres are just outside the guards (<10mm) but they help reduce mud and gravel up the sides of the cab as well. Need to clean them first.

Cut and polish the paint. Waiting until we get into the cooler weather (<28C) to do this.

Install the carpet on the rear interior wall.

I'll post some completed pics once all these are done.



Anything beyond this point is modification, which will be:

Spare tyre mounts on the tray, still working how I'm going to do this.

Water tank under the tray, ordered just waiting arrival.

Toolboxes under the tray, ordered just waiting arrival.

Install winch, all here just need to mount it in the chassis behind and under the bullbar.

Build and install scrub bars and side steps, still working on how I'm going to set these up.

Likewise I'll post completed pics of these as well.

 

Welldone to you m8. A bloody great thread and thankyou for going that extra bit to keep us up to date. You have one hellava truck Ross.