DPUK have now started selling a kit for your 2.5 engine trucks. You can buy a everything to swap the engine in a weekend from those boys. I use them for merc parts and they built me a special fuel pump. The owner luke is a real nice chap.

Ran out of projects recently so I decided to finally getting round to swapping the rear drums for discs as the truck goes very fast but stops not so fast. Got drilled grooved and vented discs on front and ebc pads which made a huge difference. So I thought if I also did the back it would twice as good.
I’m using the ends off a shogun sport axle. Only problem is the half shafts on my truck are a lot larger than standard with it being an import. Everything is bigger for some reason. So I need to swap the shafts out the rear bearing carriers. I reckon u guys with the English trucks could just do a straight swap. Only be a day job I reckon. Bild entfernt (keine Rechte)
Picture off the shaft end difference

Only issue I’ve had so far is the bearing puller. I had to make an extension. First on worked on first pull but only just. So built a massive Heavy duty one. Bild entfernt (keine Rechte)

Combine that large tool with another. A mahoosive puller I got and some added extra oxy/propane torch used to its full potential and the things fell off. Bild entfernt (keine Rechte)
Now I just got to put everything back together. But with the shafts off my axle with the hubs off the shogun and the new bearings and abs rings for my axle . Everything swaps the same bearing and shaft wise. Lucky really. Only difference is the shaft size. And no comment @123hotchef about my shaft size. I’ve also got some new back plates to make as I refuse to pay £156 a side for 1/2mm thick plates. Il put some more photos up as I reassemble

This was puller extension version one. Bild entfernt (keine Rechte)
It warped getting the first one off with heat from the torch. I put it in the hydraulic press after to straighten it and it got to 16tonne then buckled and blew out and nearly took half my face off and caused me to throw away my boxers and wash my boots out. So I thought I best stop being a useless half bodge it tool maker and make something manly.

Never messed with the rear axle much - is this set up pushing the shaft out of the bearings?

Yea. It’s pulling the bearing race off the shaft

Quote: Mallinman wrote in post #252

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Ran out of projects recently so I decided to finally getting round to swapping the rear drums for discs as the truck goes very fast but stops not so fast. Got drilled grooved and vented discs on front and ebc pads which made a huge difference. So I thought if I also did the back it would twice as good.
I’m using the ends off a shogun sport axle. Only problem is the half shafts on my truck are a lot larger than standard with it being an import. Everything is bigger for some reason. So I need to swap the shafts out the rear bearing carriers. I reckon u guys with the English trucks could just do a straight swap. Only be a day job I reckon.
Picture off the shaft end difference

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Quote: Mallinman wrote in post #257

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Yea. It’s pulling the bearing race off the shaft

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Weld the race to what??

nothing just weld it to distort/shrink it and it comes off

I see. Possibly. It took a lot of heat to get them to shift.

too late now! use stick or better still if u can get it in there tig with no filler

Got the shafts and hubs all ready to press new bearings in. Put the shafts in the lathe to give them a quick clean up and polish before the install Bild entfernt (keine Rechte)
Got em dead square in the press and 14 tonnes later.
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It works out at 12 tonne in the manual but I’m not sure the gauge is 100% correct on my press.

New handbrake shoes and cables fitted in along with discs,EBC pads and callipers. Was only £64 for 2 new callipers so wasn’t worth refurbin the old ones. There all just ready to bolt in now. Just need a free day
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Looks great! Is it run off the standard master cylinder?

That’s the plan. I think will throw enough to make everything work fine. Only time will tell

Well I’m finally on with putting the discs on. They went in spot on and everything fit and matched up. Just gotta make some new copper lines this weekend.
Thought I’d start as I killed the clutch I had made. It was a twin plate but I ripped the centres out of one of the plates. It lasted 5 years. Well it was rated for 400hp and with towing but I have been towing silly heavy recently and been thrashing the crap out the truck. I blame donuts and burn outs. Same old tho. Build, break, repair and make better.

were the shafts the same length

Yea. It was just the shaft widths. As mine are bigger than a standard 2.5 k74. Which is why I reckon they would just be a straight Swap on a standard truck.

I have a shogun sport I'll have to measure. I.think it's the and and non and that are different