Now we need an outer CV joint, or a 'dummy shaft' if the van is to be RWD.
Unfortunately, although the spline count on the D3 drive flange is the same as the Transit outer CV, the shaft diameter is different
So it looks like we will have to use the D3 outer CV and manufacture hybrid drive shafts, since our van is FWD
This is how the CV was modified to work.
Placing the D3 CV in the rear of the drive flange, it was clear that the D3 ABS ring would interfere with the swivel;
Since the ABS ring is in the wrong place for a Transit we removed it, (just hit it off with a hammer and a chisel). This is what we have now;
Now we try again;
Still some interference here;
So, we need to turn some material off the end of the CV, a 45 degree taper will do, shown by the two
RED lines;
Back to the lathe again for this lads.
While the part was in the lathe, we sorted out fitting the Transit ABS ring. The ABS ring will knock off the Transit CV, (hammer and chisel again), but the internal bore of the ring meant that it was not a tight fit on the D3 CV so could not be correctly located.
We produced a neat little ABS ring spacer;
So, while we had the D3 CV in the lathe, we cleaned up the outer face and fitted the adapter ring. Then we dressed up the outer face of the adapter ring and fitted the Transit ABS ring, here is the result;
But will it fit......
TIM