Im rebuilding my diff i have a 1200 ute diff which im wondering if any one knows about the seals that i need and if its a boag waner diff
can i fit disc brakes and what are the easist ones to fit to this diff oh and does any one have a front bummer bar

h165 diff .
not borg warner
series 2 bluebird disks are wat i have seen and heard fit the h165 diff ( wit kustom brakets ect ect )

The 1200 Ute rear axle assembly is not a Borg Warner unit, it's a Hitachi. That's what the 'H' in H165 stands for.
If you need the seal for the diff, then it's a total diff strip & rebuild job to replace it properly, but if you mean the axle seals [& not the diff] then these are available through most parts houses as well as genuine & are not hard to fit. Just follow the steps in your workshop manual.

Bluebird rear discs will fit up to the later [H165] Ute axle housing without adapters, but you need to remove the wheel bearing from the axle shaft, then discard it & the backing plate from the drum brake setup, fit the back plate from the disc brake, & install a new bearing on the axle shaft. Re-assemble as per the 910 Bluebird workshop manual.

The caliper is of a floting design, so the whole thing needs the two flexible brake hoses that come with the original disc brake, & a tab welded onto the axle housing to secure the inner ends of these hoses as well as needing the brake pipes on the axle housing shortened to suit. [after switching the banjo block to the opposite side of the housing to match the passenger car chassis.]
You will also need the longer bolts that secure the back plates from the donor Bluebird's axle housing.

Since the brake caliper in these is mounted at the top, there is some need to ensure that you have enough clearance between the caliper & the wheel housing, particularly if the vehicle is lowered.

See, it's just another straightforward 'bolt -in' deal.

That is good information and well explained Dodgeman. But what about the park brake cable ??

you can use series 1,2 or 3 bluebird disk brakes as all the wheel bearings are the same
i am unsure about the having to make up brackets as i have never had to do it

I thought Series 3 were H190? Wouldnt they be a different bearing as they have a lager axle(or do they)?

You could get away without shortening brake lines and making brakets and tabs but thats the easy and unprofecional way out

yer the H190 is a bigger axle..
the h190 is the same thickness all the way up to the bearing collar which is slightly bigger
the h165 has the same collar size as the h190 and then it has 3 different levels which get smaller and smaller

i will put up photos to show you if you want

Quote: It would also be the unsafe & illegal way.
The brake caliper 'floats' on a couple of pins the same as the fronts do, so given time, a steel bundy tubing brake pipe will fatigue & fracture. That's why the flexi hose is there in the first place on the donor vehicle.