Having searched, it looks like the splines aren't anything unusual, so it just comes down to whether the rest of the shaft would go through the axle. Guessing nobody's really needed to try! Anyone got the parts on hand for a quick trial, or at least to sit the two shafts side by side to see if...

Guessing the P38 / D2 half shafts (that is, the spline geometry, not the shaft length) aren't compatible with a D1 axle/diff?

I'm looking for a combination of half shafts, CVs and diff that might offer a bit more length between the CV joints. Are all RH inner half shafts the same length, and likewise all LH inner halfshafts the same length? Not too worried about strength (within limits) as I'm not thrashing it...

OK - bit of an update. Tried to go on holiday in the beast and, well, got 25 miles down the road before concluding that the steering was borderline dangerous. Got under the vehicle while the wife shook it from side to side. No wonder - Panhard rod bush had massive play in it. A Muslim guy...

Tightened the steering box up a bit and it's, well, OK. Not brilliant, but certainly usable. I'll see how I get on with it for a while.

Agreed. I started there and between me and a local garage, found no source outside of the steering box. Tightening the steering box adjustment briefly eliminated the problem, but it returned. When the steering box spat all of its fluid I opened it up to reveal utterly shattered lower rollers. I...

The upper roller looks healthy enough, and the lower ones are gone in favour of a plain bearing. I can't see 0.075mm bearing clearance turning into death wobble - at least, I hope not. I think the fault lies inside the box somewhere as I briefly had excellent handling with a steering box that...

Well, that's disappointing. Doesn't feel a lot better than the one it's replacing. Definitely sub-par. Adjusting the nut on top of the box helped a bit, but now I'm wondering whether the sector shaft rollers weren't the only dead bearings in there. Either that, or 0.075mm of diametral clearance...

The bearings are right down in the bottom of the steering box, and I was worried that they might act as a sump for debris to collect in. Accordingly, I cut down one of the old bearing races to about 5mm high and fitted it above where the plain bearing will go, to act as a debris trap: It's...

Here's the shaft back from the chrome plater's, shown with the oilite bush in position. They spin really smoothly together and I'm happy with the fit - any more play and it might have felt sloppy, but this aligns it without feeling tight.

Still searching...

Shaft has gone for hard chroming, but apparently you shouldn't run needle roller bearings against hard chrome. Instead, I'm having it ground to 31.675mm dia and will run it against an Oilite bush. This latter is 50mm long by 38.1mm OD (same as the bearings it's replacing, so should press fit...

Problem is that I've acquired a couple of boxes and neither has been any good. I'd rather find a way to overhaul what I've got so I know it works. Plus this might be a reasonable route for other people to follow too - costs about the same as a rebuilt box, but the money's been spent in the right...

Hope nobody minds me resurrecting a very old thread but I think this is likely the best place to keep this information for wider future reference. I went looking for the part number for the needle roller bearings at the bottom of the output shaft on a 4-bolt RHD PAS box. Now I've got home, I can...

Hi, I'm building a project truck for an African hospital (see facebook.com/swimtruck if you've a spare five minutes). I'm about to put some rear bodywork together and want to use Defender 110 sides and roof. I'm collecting a roof tomorrow but haven't yet tracked down a set of side panels. If...

That's brilliant - many thanks. A Series roof will do the job with minimal messing about. Time to go get me some panels then!

Hi, Thankyou for the response. That thread only has dimensions for SWB roofs (unless I missed them, and I did read carefully - nobody likes it when the poster just wants everyone else to do their googling for them!). If you get chance to measure your 109 tomorrow, I'd be really grateful, plus...

Thinking to adapt a LWB roof to fit my oddball project. Trouble is, I can't find dimensions on the internet anywhere, and haven't had success with the search function either. Anyone know the main measurements, i.e. length and width? Thanks in advance.

Looking to fit rear rads to the project truck. It's a 300tdi and has the the usual tentacly hoses with branches in multiple directions. I'd like to put together something simple to connect the 300tdi at the front of the vehicle with two Polo rads at the back of the vehicle and would very much...

Thankyou - I'll go ahead then! I don't have space behind the lights for the full bowls :(