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2.6l Gen 1 Front Axle Swap with Gen 1 V6 LSD - How Too - FINISHED #965403 09/28/09 03:07 AM
Joined: Nov 2008
Posts: 1,431
plh Offline OP
Body Damage is Cool
Well sort of a how to. What you will need:

Gen 1 V6 Front differential and Left Axle shaft. My donor came from my '89 SWB Raider parts mobile V6 5 speed
LSD carrier from a donor Starion / Conquest - mine was an '88.
Differential shop to do the Ring & Pinion set-up unless you know how. I brought in the parts and paid $100 (cash) <img src="/forums/images/graemlins/smile.gif" alt="" /> YMMV

Tools and a Floor Jack (at least for installing - see below)

1. Remove front 2 piece skid plate (6 bolts)
2. Unbolt front drive shaft at front differential, tuck up next to left torsion spring. Don't pull out of transfercase, you will have a leaking mess.
3. Remove 4 nuts/lockwashers holding Right Axle to RH side of front differential.
4. Remove 4 bolts holding differential crossmember to frame and 2 bolts holding crossmember to differential. I also removed the left shock - 2 bolts and a nut.
5. Drain front differential and remove cover.
6. Gently insert flat blade screw driver between end of Left Axle and spider gear shaft - wiggle to disengage the left axle snap ring. This will save a lot of tugging later.
7. Remove 2 nuts holding front differential supports.
8. OK everything is loose now, so position a floor jack under the differential to balance it, then work the unit free. Pay attention to the left axle. It should freely slide out of the dif. housing. I actually did not use a floor jack. I laid on my back on a creeper and pulled it out. My tricepts hurt <img src="/forums/images/graemlins/frown.gif" alt="" /> I think a floor jack would work better.

You should end up with this view now.
[Linked Image]

Originally I thought the Left Axle shafts were the same between the V6 and the 2.6l, but they are not. The V6 has 28 splines and the 2.6ll has 25.

V6 - 28 Spline
[Linked Image]

2.6l - 25 Spline
[Linked Image]

Here are a couple shots of the V6 8" with the LSD
[Linked Image]
[Linked Image]

and 1 of the 2.6L 7.5" Open.
[Linked Image]

Next came a bit of a frustrating part, that was how to get the Left Axle out of the hub. I messed around with jacks in multiple positions trying to get the LCA up high enough for the outside CV joint to clear enough to pull the shaft out. I was able to do this on the '89, but the '89 does not have the torsion bars cranked like the '88. I could not get it out this way so I grabbed a copy of the FSM and looked through the Front Axle service section. They show pulling the apart the tie rod and ball joints. I didn't have the recommended tools, so made a run to Harbor Freight.

I bought a Pickle Fork for the UCA ball joint as recommended and a Front End Service Kit.
[Linked Image]
This kit has various pullers that looked similar to those pictured in the FSM.

more to come...

Last edited by plh; 10/05/09 03:35 AM.

  • 88 Raider: 5 spd, 4.62 LSD F & R, T/L, OME Rear Springs, KYB G/A, 33/12.5/15" MTZs, PLH LOs, Justice Bumper, Dual Bouncies, 4D56T in -running soon!
  • 1992 RS M/T
  • 1993 SR
  • 2005 Montero LTD
  • Gen 1 - PARTS FOR SALE
  • http://www.tuffpans.com
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Re: 2.6l Gen 1 Front Axle Swap with Gen 1 V6 LSD - How Too [Re: plh] #965404 09/28/09 03:41 AM
Joined: Feb 2005
Posts: 7,387
rxinhed Offline
Trail Leader
*****
Thanks for the info. This is a project I'll likely tackle with my V8 Monty SWB. I have a chassis that I'm going to build, then swap the body tub over. Cool!

Re: 2.6l Gen 1 Front Axle Swap with Gen 1 V6 LSD - How Too [Re: rxinhed] #965405 09/28/09 03:47 AM
Joined: Nov 2008
Posts: 1,431
plh Offline OP
Body Damage is Cool
9. Remove the brake caliper mounting bolt, swing it up and remove the pads then remove the 2 bolts which mount it to the steering knuckle and the philips screw which holds the dust shield to the mount. Pull the caliper assemble away from the rotor and tie it up to the UCA using string. Be careful to not stress the rubber brake line.

10. Remove the cotter pin from the Tie Rod castle nut and take off the nut, then I flipped it around and screwed it partially back on the tie rod. I grabbed this puller from the kit

[Linked Image]

Between the top of the nut and the puller bolt I inserted a 1/8 piece of steel to protect the bolt and nut while pressing the tie rod out of the journal.

11. Place a bottle jack under the LCA. Jack it up until touching the LCA but do not apply much pressure. It is just there for support after the ball joints are unleashed. Remove the LCA ball joint cotter pin and castle nut. I used the same tool as on the tie rod end. Again flipping the castle nut and partially threading it back on and using the same 1/8 piece of steel to protect. This will only pop the shaft out of the steering knuckle at this point.

[Linked Image]

12. Remove the UCA ball joint cotter pin and castle nut. The FSM says to use a Pickle Fork. Well this was useless. I beat the snot out of the pickle fork on the UCA ball joint and could not get it to dislodge. So I grabbed this tool from the HF kit and it worked very well. Again following the bolt/nut protection described above.

[Linked Image]

When this ball joint pops, there was a bit of a bang as the LCA loaded against the jack.

13. Now you can easily position the steering knuckle to be able to slide the axle out of the hub.

Here are a couple photos with everything apart.

[Linked Image]

[Linked Image]

[Linked Image]

[Linked Image]

14. Reinstalling the V6 Differential Housing. Get a Floor Jack! I struggled for over an hour trying to get this 125+lb slippery pig wedge up in place by laying on my back under the vehicle. I ran out of daylight for today. No success. I am planning to get a floor jack to go at it again tomorrow evening.


  • 88 Raider: 5 spd, 4.62 LSD F & R, T/L, OME Rear Springs, KYB G/A, 33/12.5/15" MTZs, PLH LOs, Justice Bumper, Dual Bouncies, 4D56T in -running soon!
  • 1992 RS M/T
  • 1993 SR
  • 2005 Montero LTD
  • Gen 1 - PARTS FOR SALE
  • http://www.tuffpans.com
Re: 2.6l Gen 1 Front Axle Swap with Gen 1 V6 LSD - How Too [Re: plh] #965406 09/28/09 04:04 AM
Joined: Nov 2008
Posts: 1,431
plh Offline OP
Body Damage is Cool
As a notation to the above, If I would have known how deep into the Steering Knuckle I had to get to remove the axle, I would have had the following additional swap parts ready:

1. Gen 2 Upper Control arms (just 2 more bolts and the brake line support to remove and replace.

2. Gen 2 Steering Knuckles and Disk Brake Assemblies.

Well at least I have to tools now... <img src="/forums/images/graemlins/smile.gif" alt="" />


  • 88 Raider: 5 spd, 4.62 LSD F & R, T/L, OME Rear Springs, KYB G/A, 33/12.5/15" MTZs, PLH LOs, Justice Bumper, Dual Bouncies, 4D56T in -running soon!
  • 1992 RS M/T
  • 1993 SR
  • 2005 Montero LTD
  • Gen 1 - PARTS FOR SALE
  • http://www.tuffpans.com
Re: 2.6l Gen 1 Front Axle Swap with Gen 1 V6 LSD - How Too [Re: plh] #965407 09/28/09 03:12 PM
Joined: Jun 2003
Posts: 7,355
MontyMcV Offline
Trail Leader
Quote
LSD carrier from a donor Starion / Conquest - mine was an '88.


You also mention spline differences between 2.6 and 3.0. Which CVs you use depends on your SQ donor. As you know, your 88 matched the V6's. If the donor is an 87, you need the I4 CVs. (Earlier donors require other/different setups. Search past threads as needed if you are reading this one.)


Big Truck: 00, 3.5, Endeavor, 5-Spd drive line in hand!
Little Truck: 87, 2.6T I/C, MT, LSDs, Tonneau Top
Her Truck: 03, 3.8, 20th Anniv, 65k
Daughter's: 06 Eclipse, Keeping it Mitsu!
FSMs: MitsubishiLinks.com
Re: 2.6l Gen 1 Front Axle Swap with Gen 1 V6 LSD - How Too [Re: plh] #965408 09/28/09 03:40 PM
Joined: May 2000
Posts: 6,132
K
Kevin C Offline
Trail Leader
****
I'm sure you also know that the cross 4 cyl member needs to be modified where diff mounts. The cross member from the V6 has a differant bolt pattern where it mounts to the frame and does not line up.

Kevin


87 Turbo Intercooled Raider, roller cam, torsen rear diff, LSD front diff, lockup auto with modified converter, V6 brakes, low transfer case gears...
Re: 2.6l Gen 1 Front Axle Swap with Gen 1 V6 LSD - How Too [Re: Kevin C] #965409 09/28/09 04:39 PM
Joined: Jun 2003
Posts: 7,355
MontyMcV Offline
Trail Leader
Good reminder. Rather than deal with the xmember, I redrilled the tab on mine. Also trimmed down the taller top bushing.

[Linked Image]

[Linked Image]


Big Truck: 00, 3.5, Endeavor, 5-Spd drive line in hand!
Little Truck: 87, 2.6T I/C, MT, LSDs, Tonneau Top
Her Truck: 03, 3.8, 20th Anniv, 65k
Daughter's: 06 Eclipse, Keeping it Mitsu!
FSMs: MitsubishiLinks.com
Re: 2.6l Gen 1 Front Axle Swap with Gen 1 V6 LSD - How Too [Re: Kevin C] #965410 09/29/09 02:23 AM
Joined: Nov 2008
Posts: 1,431
plh Offline OP
Body Damage is Cool
Quote
I'm sure you also know that the cross 4 cyl member needs to be modified where diff mounts. The cross member from the V6 has a different bolt pattern where it mounts to the frame and does not line up.


Nope I didn't know this. I still have the cross member from the '89 so shouldn't be a problem.

Crap weather today, 55F and rain. Tomorrow should be dry. Stopped at HF again and bought this transmission jack. Jack on sale at the local for $74. Figured it was worth it. I still need to pull the 5 speed and transfer case out of the '89 so it should come in handy for that too. I work alone so it will be better than dropping it on my head <img src="/forums/images/graemlins/drunk.gif" alt="" />


  • 88 Raider: 5 spd, 4.62 LSD F & R, T/L, OME Rear Springs, KYB G/A, 33/12.5/15" MTZs, PLH LOs, Justice Bumper, Dual Bouncies, 4D56T in -running soon!
  • 1992 RS M/T
  • 1993 SR
  • 2005 Montero LTD
  • Gen 1 - PARTS FOR SALE
  • http://www.tuffpans.com
Re: 2.6l Gen 1 Front Axle Swap with Gen 1 V6 LSD - How Too [Re: plh] #965411 09/29/09 03:05 AM
Joined: May 2000
Posts: 6,132
K
Kevin C Offline
Trail Leader
****
Just to be sure.. A V6 crossmember wont bolt up to a 4 cyl frame, you will have to mod the 4 cyl cross member.



Kevin


87 Turbo Intercooled Raider, roller cam, torsen rear diff, LSD front diff, lockup auto with modified converter, V6 brakes, low transfer case gears...
Re: 2.6l Gen 1 Front Axle Swap with Gen 1 V6 LSD - How Too [Re: Kevin C] #965412 09/29/09 03:25 AM
Joined: Nov 2008
Posts: 1,431
plh Offline OP
Body Damage is Cool
Quote
Just to be sure.. A V6 crossmember wont bolt up to a 4 cyl frame, you will have to mod the 4 cyl cross member.


Every day I learn something. Thanks for the info. <img src="/forums/images/graemlins/cheers.gif" alt="" />


  • 88 Raider: 5 spd, 4.62 LSD F & R, T/L, OME Rear Springs, KYB G/A, 33/12.5/15" MTZs, PLH LOs, Justice Bumper, Dual Bouncies, 4D56T in -running soon!
  • 1992 RS M/T
  • 1993 SR
  • 2005 Montero LTD
  • Gen 1 - PARTS FOR SALE
  • http://www.tuffpans.com
Page 1 of 5 1 2 3 4 5







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