I have fitted the back axle, an Atlas Cortina axle with the 4 link suspension. For now it's bolted up but without springs, the chassis is on stands. I can lift and lower the axle to check movement and clearances.
I have also trial fitted a bare block and a gearbox with the intention of measuring the propshaft length.
Therein seems to be a problem... The propshaft length with the back axle at it's lowest position, or car at it's highest, is 35 inches face to face. When I raise the axle to it's highest, or car at lowest, the propshaft length face to face is 33 inches. A difference of 2 inches, or 50mm.
I have measured the propshaft I removed and that has only about 22mm of slide movement in it's length (it's a strange form of CV. Until I get the photo's sorted you will have to use imagination!). I have a number of Land Rover propshafts, I have measured them and they only have about 40mm of travel in their splines.
The front UJ/CV joint.
Rear UJ.
Am I right in thinking that the donor Cortina gearbox would not have had an output flange but a spline shaft instead? That could mean the propshaft had more extension capability than a flanged propshaft.
The mid shaft weld, and balancing Jubilee clip?
The full propshaft:
I would say in active use the dynamics of suspension movement could create more movement still so the propshaft needs to have plenty of reserve movement.
Going back to the radiator for a moment, I believe the reason the water pump has been trying to drill through the radiator, apart from it being very close to start with, is that the propshaft has been pushing the gearbox and engine forward significantly due to the suspension travel and the movement of the axle back and forth.
Water Pump and Radiator in close proximity.
Finally, one fault I have noticed is there is a considerable leakage of oil from the region of the axle input drive flange. At first I suspected the oil seal but I am now wondering if the oil is coming out via the splines and under the flange attachment nut, it was very wet between the propshaft and the axle input flange, does anybody have any experience of this with Ford axles? I also wonder if the forces imposed by having a propshaft which can't accommodate the axle movement have had a hand in causing the leak. The propshaft is very badly welded, in the centre, it must be out of balance, a Jubilee clip has been fitted, presumably to try to balance the shaft but I expect it's not straight so it will take more than a Jubilee clip to balance it I think.
Any thoughts please?