Homemade Diff Drop for 6G Bronco

[Tex]

SCS actually offers a bending service in addition to their cutting. End user would really only have to run a few beads when they get the kit.

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[orion]

SCS actually offers a bending service in addition to their cutting. End user would really only have to run a few beads when they get the kit.

@TeocaliMG, I vote make it happen.

 

[TeocaliMG]

Right, thanks for the reminder. I saved the video for later as the kids were watching Spiderman.
Is that rear mount bound up at all after the drop? Or is it negligible since it has a rubber bushing? Either way, kit looks great.

Total rotation of the differential was around 4ish°. So, there is a little bit of windup in the bushing, but I think its negligible.

 

[TeocaliMG]

That's a nice looking part....But.... what about the other 2 mounts??? the rear need dropped also or your axle is only dropping about have of whatever your front mount drop is. because the axle is halfway in between the front and rear mount...

I go into more detail in the video. (skip to 13:38)

The other two mounts were handled with these parts:

I didnt actually lower the rear mount like you did. Instead, I extended it forward, this allowed me to get more rotation out of the diff, and handle the right side with a simple spacer. Seems like the easiest way to go about it for a drop in the area of an inch. If you want to go lower, you need to do more. Also, shifting the diff forward removes a bit of unnecessary CV angle just from having the diff positioned slightly rearward of the wheel center, but thats probably negligible.

It was all done up in CAD. Half inch (12.7mm) forward shift. 4° rotation, 12.6mm on the right spacer (accidentally said 16mm in the video), and 32.9mm drop on the front bracket to achieve an axle center drop of 20mm. And because the front mount sits considerably higher than the bottom of the diff (stock) you can do more drop there (with rotation) with no penalty to net ground clearance over the centerline drop of 20mm.

 

[BigMeatsBronco]

cool, guess I missed the 32.9 mm drop on the front bracket...
looks like I need to move mine back to OEM for Braptor suspension parts...

I think the passenger side really need a double shear mount instead of a "hanger"

looking at beefing that up.

 

[mpeugeot]

I was just thinking about this very topic this morning.

 

[TeocaliMG]

cool, guess I missed the 32.9 mm drop on the front bracket...
looks like I need to move mine back to OEM for Braptor suspension parts...

I think the passenger side really need a double shear mount instead of a "hanger"

looking at beefing that up.

I dont think the load on that side is exceedingly high, but shouldn't be too hard to fab up a double shear bracket for it either.

 

[FowlBronco77]

Greta job! Very impressive

 

[AttackGuy64]

Coming from a place of ignorance here. If we only drop the front of the diff, doesn't that change the pinion angle? How much does the diff drop change that angle and is it still acceptable?

 

[TeocaliMG]

Coming from a place of ignorance here. If we only drop the front of the diff, doesn't that change the pinion angle? How much does the diff drop change that angle and is it still acceptable?

Valid question, I don't know what the driveshaft CV's can handle. I think it's safe to assume they can't handle 30 degrees like the halfshaft CV's but they were already extremely low angle, like a couple degrees, and I only rotated the diff about 4 degrees forward. So the angle at the front of the driveshaft is about 6°. Not too worried about that.

 

[Fordified1]

I would add that pinion angles and timing for CV joints are less critical than normal u-joints. (in regards to vibration)

 

[mpeugeot]

Coming from a place of ignorance here. If we only drop the front of the diff, doesn't that change the pinion angle? How much does the diff drop change that angle and is it still acceptable?

https://www.bronco6g.com/forum/threads/teraflex-jl-cv-joint-adapted-to-bronco-confirmed-fit.89634/

This is how you might address the issue.

 

[Dusty]

Awesome work! I'm in for the full kit. I like the idea of the cut & bent pieces drop-shipped from Send-Cut-Send, in U-Weld-It form

 

[NORCALGXP]

Build it I will buy it. I need it.

 

[TeocaliMG]

Here are more details on the skid plate.
For those interesting in more details, don't hesitate to PM me. I'm working on a kit, but if you want to try it yourself, I can give you the measurements.

I just used a cutoff wheel, starting point "A" is roughly at the crease between the two forward driver side mounts. Cut a straight line to the bottom of that same crease, where it levels off with the bottom of the skid "B", roughly in line with where the start of the original differential clearance hole starts. Cut straight back to "C" along the lower crease for about 1-1.5". Cut from "C" to "D" at a 45° angle to the diff clearance hole.

Begin the next cut "E" on the passenger side of the centerline of the diff clearance hole, about an inch inboard of the passenger side of the clearance hole. Cut back to "F" about 0.5", then cut towards the knotch in the skidplate on the drivers side "G".

Remember to cut conservatively as little as possible. Its relatively easy to hold the skid up in place (with a couple bolts in) to check fitment. Remove as little as possible to save as much strength as possible.

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