To: Volvo303@yahoogroups.com From: "najw992000" Date: Tue, 13 Jul 2004 18:47:24 -0000 Subject: [Volvo303] Difflock Acuator Reply-To: Volvo303@yahoogroups.com Can anyone shed more light on the conversion of the axle difflock actuator to Range Rover parts? Presumably this is the vacuum operated centre difflock unit. How much work is needed to make it fit? Any info or links would be appreciated. Neil PS: Still looking for new rubbers for the original Volvo actuators To: Volvo303@yahoogroups.com From: "Willem-Jan Markerink" Date: Tue, 13 Jul 2004 21:03:17 +0200 Subject: Re: [Volvo303] Difflock Acuator Reply-To: Volvo303@yahoogroups.com On 13 Jul 2004 at 18:47, najw992000 wrote: > Can anyone shed more light on the conversion of the axle difflock > actuator to Range Rover parts? Presumably this is the vacuum operated > centre difflock unit. How much work is needed to make it fit? *If* the Volvo actuators are indeed single-operated/spring-loaded, then I would try to convert to a mechanical cable-operated mechanism. (a cable-control *can* be dual-operated (push/pull), but I am not sure how much force can be transferred that way (and/or how thick/rigid the cable would become) Try finding a large agricultural or aerotechnical shop for such parts. (similar concepts are used for Land Cruiser diesels, when changing from the electro-mechanical line-pump control (reliable, but expensive to replace) to cable-control) -- Bye, Willem-Jan Markerink The desire to understand=20 is sometimes far less intelligent than the inability to understand [note: 'a-one' & 'en-el'!] To: Volvo303@yahoogroups.com From: N*A*M Date: Thu, 15 Jul 2004 10:54:17 +1000 (EST) Subject: Re: [Volvo303] Digest Number 358 Reply-To: Volvo303@yahoogroups.com > Can anyone shed more light on the conversion of the axle difflock > actuator to Range Rover parts? Presumably this is the vacuum operated > centre difflock unit. How much work is needed to make it fit? > > Any info or links would be appreciated. > > Neil > PS: Still looking for new rubbers for the original Volvo actuators Neil, I will forward this to someone that might know the answer and get b= ack to you. Rgds, Nam To: Volvo303@yahoogroups.com From: N*A*M Date: Thu, 15 Jul 2004 17:15:59 +1000 (EST) Subject: [Volvo303] RR Vacuum Servo Reply-To: Volvo303@yahoogroups.com Neil, Please read Bill Larman's reply below. Rgds, Nam I am going to try to describe the vacuum servo conversion as best I can without measurements at this stage . I can post these later when I measure the sample. Step 1 - remove differential and portal assemblies. Step 2 - remove old Volvo vacuum servo. keep hollow retaining bolt. Step 3 - remove difflock bell crank from banjo housing. Step 4 - screw servo retaining bolt back into banjo housing and using a drill bit the same size as the RangeRover vacuum servo pushrod, open up hole in banjo housing. Step 5 - using a 25mm hole saw cut hole in top of Rangey servo unit. Offset hole away from vacuum pipe fitting. This hole will later be covered by a 25mm rubber blanking grommet. Step 6 - clamp servo pushrod in a vice and with a 13mm socket unscrew the bolt that retains pushrod to diaphragm. Step 7- with cutoff wheel on angle grinder cut pushrod off through centre of 2nd detent groove. Step 8 - drill a 6mm hole in end of pushrod right through to threaded hole. Step 9 - if you have an old centre difflock selector box, carefully saw off the servo mounting flange and file or machine the cut flat so that it is flat. Step 10 - you must drill out the pushrod hole on this flange so that the threaded part of the Volvo servo retaining bolt will fit through. Step 11 - Machine the the hexagonal head of the Volvo retaining bolt until it is round. If you have a lathe you can spotface the top of the bolt to accept the rubber "o sealing ring. If not you can use a countersinking drill to a depth of about 1mm. Step 12 - Now measure the diameter of the retaining bolt head and contersink one side of aluminium flange to this diameter and just deep enough so that when the retaining bolt is fitted into the hole its head is flush with surface of flange. The other steps involve cutting the Volvo pushrod, pushing it through the shortened Rangey pushrod and applying a dob of weld to it, but I do not have the measurements at the moment, so I will leave it there for now. When fitted together, the Volvo pushrod must wobble in the Range pushrod so that it aligns itself without binding as the bellcrank moves from the lock to unlock position. I apologise for the vagueness of these instructions but as I said before, it is difficult without photos, or a sample in my hand that I can take measurements from. Regards Bill.