front diff

John even though I'm "mechanically challenged" I do drive an 80 so I'll kick off the replies. First thing I'd do is see the experts and find out whats wrong with the front end. You don't want the wheels falling off ..besides that would give the rest of us a bad name :))
AFAIK changing the front to a manual system will only reduce wear/fuel consumprion (slightly), not fix existing problems.

its normal to have back lash in the front diff . Just make sure your pinion bolt is tight, as they have a tendancy to come loose.

Dont forget that if you want to do manual hubs , there is alot you need to replace to get it up to scrach .

Once your front diff is appart , if you want to get it up to scrach , you need to inspect and probably replace the following

Front CV's
Both front axles ( you will find they are tee peed at the splines)
Swivel bearings
Axle seals
wheel bearings
swivel housing gasket kit

On top of this , you need to get a manual hub conversion kit.

Hope this helps

Mate,

I have just gone through the expensive process of replacing the front diff on my 91 GXL 80 Series. The diff and axel splines were worn beyond repair. Cost over $2000 to fix. Before I did the repair the black lash wasn't too bad but now with all new diff and axels I do feel the difference.

I am coming up to my next service soon and I am going to change to manual hubs, even if it only reduces the amount of ware I would be happy.

I drive a 2001 100 Series Standard for work (with manual front hubs) which is basically the same running gear as the 80 Series and there is no blacklash at all.

Do have your front diff checked before doing anything esle because it might be on it's way out. To do a quick test for yourself - get underneath the car and twist the front drive shaft. If it moves more than 1/8 of a turn then your diff needs looking at.

If you do need to have your diff replaced then I would replace the hubs then - less cost as everything has to be pulled down anyway.

Hope this helps.

Karl.

Why should they be worn as they do little work except when in 4WD?
Is it because they are auto hubs & running all the time.
My Triton with 240,000 kms & man hubs seems tight at the front axle.