I have Ashcroft HD CV's and Maxi Drive ABS tone rings intended for AEU 2522's. I'd like to mate them, but the Ashcroft CV's OD is almost a mm larger than the ID of the rings.

My plan is to file a chamfer on the inside of the rings, put the CV's in the freezer and the rings in the oven, and then bang them together with a copper mallet.

Is this a decent plan, or will I destroy the rings in the process? Steel quality unknown, but they are not heat treated. I have an old ring that was slightly stretched but didn't break when a genuine AEU 2522 failed, so I am inclined to think that it will work?

For those familiar with these parts, I plan on using new style rings and mount them backwards with the old style mounting tool to clear the big chamfer on the Ashcroft CVs.

Oh yeah, ABS is a prerequisite for street legality, so don't get started on the merits and disadvantages of ABS. :flipoff2:

i think the rings are made from 4140?

serg

I would expect something like that for the reinforcement rings, but are you sure that the ABS rings with the milled grooves are of such high quality?

Assuming 4140, will I be able to mount them despite the tight fit? Only light tapping with some green Loctite on is required to mount them on genuine AEU 2522's, so I would expect that a slightly larger OD CV would work?

i think the rings are made from 4140?

serg

If the difference in OD is much greater than that expected on the real 2522s, you run the risk of having the exciter ring crack or otherwise fracture as it contracts.

How great a difference are we talking here? a few thou? or tens of thou?

i'm a machinist. putting the cv in the freezer and the ring in the oven, assuming your freezer is 0 which it probably isn't, will only giver you maybe .005 max per part to play with. not anywhere near 1mm. depending on the class, press fits vary from .0002 to .007. any more than that and one of your pieces has to give.

See orginal post, PT. Sligthly less than one mm. That would
be about 40 thou to those who resist global standards. :flipoff2: I believe I can temporarily get that down to about 0.5 mm with the freezing and heating routine. Still pretty tight.

The one that was on the genuine AEU2522 that failed didn't crack when it stretched. Material thickness in the rings is only a few mm. Ooh, about 1/8". I don't know to what tolerances genuine CV's are manufactured. Maybe my old ones are on the small side and everything is within limits?

If the difference in OD is much greater than that expected on the real 2522s, you run the risk of having the exciter ring crack or otherwise fracture as it contracts.

How great a difference are we talking here? a few thou? or tens of thou?

The ring is thin and not really structural. If I can just get it in the right position before it seizes, I'm not too worried by a little plastic deformation in the ring. If it is uniformly distributed...

I don't want to machine the higly polished CV, and I don't think I the ring will still be round if I mount it in a lathe. I guess I'll have to resort to physical abuse to get the rings mounted...

i'm a machinist. putting the cv in the freezer and the ring in the oven, assuming your freezer is 0 which it probably isn't, will only giver you maybe .005 max per part to play with. not anywhere near 1mm. depending on the class, press fits vary from .0002 to .007. any more than that and one of your pieces has to give.

Sligthly less than one mm. That would
be about 40 thou to those who resist global standards. :flipoff2:

ER, that couldn't have been directed at me as I'm the one who campaigns for the use of UTC, if not the metric clock, along with my stubborn use of the ISO date/time standard.

Yes, I am both QS and ISO certified as an auditor! Can't get much more global standard than that!

(now I see the almost a m/m difference)

No serious harm intended, PT. The saga continues. I managed to get one ring off from a genuine AEU2522 where I had mounted it with green Loctite. Only hand tools and a heat gun needed. I think there is hope to mount the rings on the real CV's with determination and some uber-violence.

[ER, that couldn't have been directed at me as I'm the one who campaigns for the use of UTC, if not the metric clock, along with my stubborn use of the ISO date/time standard.

Yes, I am both QS and ISO certified as an auditor! Can't get much more global standard than that!

(now I see the almost a m/m difference)

No serious harm intended, PT.

[

None taken, either. It was such a shock for ME to be seen as resistant to anything even approaching an "international Standard" that I had to respond.

it can be done and has been done.

i spoke to Mal today and he did this recently for a customer that has ashcroft cv's

first of all, the ABS TONE RINGS are made from hollow bar NOT 4140

the REIFORCING RINGS are made from 4140

he made up a collet to fit over the tone ring so he could put it in a lathe and machine it to fit the cv's

made from some heavy wall pipe as far as i could tell. about 20mm wall and cut a slit in it so it would clamp up on the ring. he said make it nice and heavy so it won't deform.

cheers, serg

Thank's. I left them today with a fellow trialler and trusted mechanic to machine the inside of the rings. It will be a few weeks before I get them back.

it can be done and has been done.

i spoke to Mal today and he did this recently for a customer that has ashcroft cv's

first of all, the ABS TONE RINGS are made from hollow bar NOT 4140

the REIFORCING RINGS are made from 4140

he made up a collet to fit over the tone ring so he could put it in a lathe and machine it to fit the cv's

made from some heavy wall pipe as far as i could tell. about 20mm wall and cut a slit in it so it would clamp up on the ring. he said make it nice and heavy so it won't deform.

cheers, serg

The cheap ass Wilsby has not gotten around to cough up for his star, yet, so he asked me to post these for him:

Thank's Tobias!

These are the old style (as in AEU2522 lookalike) HD CV's from Ashcroft with machined out (~1 mm) ABS rings from Maxi Drive. New style rings mounted backwards with the old style mounting tool to clear the larger chamfer on Ashcroft's CV's.

I can carry my genuine AEU2522's as drop in spares, which is a big bonus to me. I can also install stock LR halfshafts to get me home from faraway places if anything should break.

But I think my MDE locker w 3.8 gears from KAM, MDE halfshafts and drive members, and now HD CV's from Ashcroft will last a while. And I have operational ABS, and can thus pass the periodic road safety inspection.

The cheap ass Wilsby has not gotten around to cough up for his star, yet, so he asked me to post these for him:

Hi Wilsby

Let us know how you go with this.

We did the same conversion, & now can't get the dashboard lights to go out. There is something causing the CVs to run in an oval fashion, bad enough to damage the sensors.

Mal fitted the rings for us late last year - 2 cars, both with the same problem. I doubt the problem is with Mals work or the CVs themselves, but we can't see what's causing this.

Regards
Max P

I hate ABS rings and sensors Ford has the worst:evil:

We'll see, but not anytime soon. The 110 sits outside in about 1/2 a meter of snow.

Did you locate the rings exactly where I did? This seems to be the right spot, comparing to genuine AEU2522's.

Do you use Mal's bronze bushings inside the spindles, or do you have old style spindles? I have used Mal's bushings with genuine CV's, and will renew the bushings before install.

My ABS has acted up for periods. It likes to have fresh wheel bearings, radius arm bushings, shocks and tight bronze bushings. I have also had some succes tying the sensors down with steel wire when the system was marginal.

My machinist was afraid of warping the rings on install, so he machined them so they basically slid on the CV's and glued them in place w Loctite. You still make me nervous...Hi Wilsby

Let us know how you go with this.

We did the same conversion, & now can't get the dashboard lights to go out. There is something causing the CVs to run in an oval fashion, bad enough to damage the sensors.

Mal fitted the rings for us late last year - 2 cars, both with the same problem. I doubt the problem is with Mals work or the CVs themselves, but we can't see what's causing this.

Regards
Max P

We'll see, but not anytime soon. The 110 sits outside in about 1/2 a meter of snow.

Did you locate the rings exactly where I did? This seems to be the right spot, comparing to genuine AEU2522's.

Do you use Mal's bronze bushings inside the spindles, or do you have old style spindles? I have used Mal's bushings with genuine CV's, and will renew the bushings before install.

My ABS has acted up for periods. It likes to have fresh wheel bearings, radius arm bushings, shocks and tight bronze bushings. I have also had some succes tying the sensors down with steel wire when the system was marginal.

My machinist was afraid of warping the rings on install, so he machined them so they basically slid on the CV's and glued them in place w Loctite. You still make me nervous...

We'll swap some of your snow for some of our drought..

Its all coming apart again next week, I'll check the position of the rings. Unlikely Mal got it wrong though. I'll check the leftover 2522 too.

We used the extra piece Mal made up as directed in his instructions, can't be sure about the spindles though.

All suggestions welcome!

TIA & regards
Max P

I'd start looking for slop in the axle assembly, at the spots mentioned above and maybe drive flanges and svivel pin bearings. Anything that shifts may be detected as an inconsistent flow of ABS pulses.

Agree that Mal's work is not the likely culprit.

We'll swap some of your snow for some of our drought..

Its all coming apart again next week, I'll check the position of the rings. Unlikely Mal got it wrong though. I'll check the leftover 2522 too.

We used the extra piece Mal made up as directed in his instructions, can't be sure about the spindles though.

All suggestions welcome!

TIA & regards
Max P

Am I crazy to think that a glued on ABS tone ring is a bad idea?

I am using Ashcroft's HD 2522 w/ no ABS ring. I would think that a glued on ring could come off and cause catastrophic damage! What kind of rpm does a cv undergo at 70 mph?!

Green Loctite and a tight fit. Don't worry, that's the way it's done. Just had to adjust the ID to the new CV.

There is no stress, regardless of RPM.

Am I crazy to think that a glued on ABS tone ring is a bad idea?

I am using Ashcroft's HD 2522 w/ no ABS ring. I would think that a glued on ring could come off and cause catastrophic damage! What kind of rpm does a cv undergo at 70 mph?!

Epilogue:
Finally got around to button up the front axle yesterday, and ABS seems to work fine. I did change to fresh bronze bushings in the spindles. The old ones were worn, and I think that is a factor for stable ABS. I do have some flicker/glow in the ABS light on hard acceleration, but that is an old issue and I think I have a wire partially grounding somewhere, not a real ABS issue.

Am I crazy to think that a glued on ABS tone ring is a bad idea?

I am using Ashcroft's HD 2522 w/ no ABS ring. I would think that a glued on ring could come off and cause catastrophic damage! What kind of rpm does a cv undergo at 70 mph?!

Nope, it'll be fine.
The only thing that'll cause greif is if it gets hot enough to destroy the loctite (above boiling point). If that's happened, you've got serious issues anyway.

Hi,

we now have the shorter later type Heavy duty CV in stock with the ABS rings if anyone else is watching this who wants HD CV's and to keep the ABS,

Hi,

we now have the shorter later type Heavy duty CV in stock with the ABS rings if anyone else is watching this who wants HD CV's and to keep the ABS,

Dave, what is the difference in strength between the two types HD CV's?

Dave, what is the difference in strength between the two types HD CV's?

x2