Member Since: 22 Apr 2012
Location: Rome
Posts: 2321
Rear diff overhauling
Today i have assisted my mechanic during reardiff opening,
since i can heard a noise similar to the water streaming in a pipe from the diff we decided to check inside to know what was the issue.
3 bearings on 4 were damaged on their crown, 2 were worn and one presents a damage on the sliding material (probably a building issue).
The labour is quite difficult , bearings need to be heated up before use a puller and also pull out and then fit the new crowns could be a mess.
An hydraulic press is needed to refit the main bearings on the pinion and finally a very good skill is necessary to tight at the right torque the pinion bolt which is responsible of the correct tension on the bearings and the correct coupling on his crown.
A new set of Timken bearings and washer is now refitted, tomorrow the diff will be in place and the silence will come again inside my disco.
Unless you know very well what to do, my thought is that the overhaul is a bit too difficult for a DIY job,
finally i have payed 150 pound for the Timken kit on flybay - Easy-Lift suspension module 4.0
- GoodWinch 9500 lb
- Full underbody protections
- Tree/Rock sidebars
- Prospeed roofrack & ladder
- Compressor guard
- Raised Air Intake
- Driving lights (2+4)
- 50 mm Waffle boards
- Altox Heater control
- Overland Rooftop Tent
- Rear seats entertainment
- Front & Rear camera
- GVIF
- Removable tow bar
- Cubby box fridge
- BFG KO2 265/65R17
- iidTool BT
28th Oct 2016 6:43 pm
SafariDave
Member Since: 19 Nov 2011
Location: NYC & LA
Posts: 775
Had my reardiff rebuilt last month at 102K miles.D3 2005 V8 SE Bonatti Grey "The Rhino" (our NYC D3)
De-tangoed Headlights, D4 2016 Style Black Pack Grille, D4 19" Wheels/ Bridgestone Alenza
D3 2005 V8 SE Bonatti Grey, D4 2016 Style Black Pack Grille (our LA D3)
D2 1999 V8 SD7 Chawton White (our Caribbean Beach truck)
Had my diff rebuilt a few days ago as it was very noisy especially around 90 kph
DIY removing and refitting has been a real PITA
Click image to enlarge
inside the paint was mixed with the oil (even if I flush it every year) closing the oil passages to the pinion bearings
Click image to enlarge
this is a view of one of the pinion bearing housing
Click image to enlarge
everything else was ok
got it rebuilt by a local diff mechanic at a reasonable cost but I supplied the overhaul kit
he replaced every bearing even if the only one damaged was one of the pinion ones
F.
30th Oct 2016 5:32 pm
Sidestick
Member Since: 22 Apr 2012
Location: Rome
Posts: 2321
Could a Galvanic parasite current cause this material deterioration?
Like on a boat, rotative parts generate static current causing micro voltaic arch which discharge over bearings,
Could be a good idea to connect the diff to the chassis via an earth cable?- Easy-Lift suspension module 4.0
- GoodWinch 9500 lb
- Full underbody protections
- Tree/Rock sidebars
- Prospeed roofrack & ladder
- Compressor guard
- Raised Air Intake
- Driving lights (2+4)
- 50 mm Waffle boards
- Altox Heater control
- Overland Rooftop Tent
- Rear seats entertainment
- Front & Rear camera
- GVIF
- Removable tow bar
- Cubby box fridge
- BFG KO2 265/65R17
- iidTool BT
This is an interesting point to discuss any way IIRC there is more than one earth to the chassis.
One is connected to the transfer case and the differential is not far from there (attached to the TC via the prop shaft).
Any way I recently looked for parasitic currents using Robbie's how to and found everything was ok.
I found a normal 0,01 to 0,02A absorption in sleep mode.
F.
1st Nov 2016 9:15 am
Discoveringcomfort
Member Since: 16 Sep 2015
Location: Berkshire
Posts: 637
Pain in the ass to remove and refit!
I have just spent three days with just the exhaust removal and repair prior to removing the diff!
Great design, the V8 exhaust has two pipes from the cats, one has a sliding pipe connection the other has a two bolt flange connector.
The sliding connector has a circular exhaust clamp that is spot welded the the pipe and a bolt that once the nut is undone does not release. This required the spot weld drilling out and the clamp grinding off.
The two bolts in the flange joint are welded to the flange and snap when the nuts are undone. No sweat thinks I, I will just drill tem out and fit new bolts! Not a chance, the bolt head is not tacked on it is fully robot welded, this case hardens the bold head, three sets of drill bits later (kept cool and resparpened) and still the hole is too small for new bolts. In the end I had to get the drill bit red hot untill I could see the sparks of the carbon burning out of the steel before the bit would burn its way through!
What if this had happened at a dealer or indie they would charge for a new exhaust system just because of three bolts!
The diff bolts are all undo able which was a concern but so far the diff has not looked to be loose even though the bolts are.
Lastly why unearth did JLR fit a welded nut locking plate on the front bush bolt it is the easiest bolt to get to on the whole vehicle but prone to corrosion and the nut which is not actuall captive is not an orderable part as it does not exist in the parts list!
Phew,
As I finally got the exhaust back in a fitable condition and the whole family was clostraphobic in the Clio I gavee up the diff removal for this week and refitted the exhaust, even my four year old who likes the little car announced that the big car is his number one car!
PS and OT
At three my son learned to regognise the green oval and he gleefully anounced how many LR cars he counted in the car parks. Class boy!Series 1 V8
Series 2 Hibrid V8
Discovery 3 HSE V8
Member Since: 23 Dec 2013
Location: under the car
Posts: 404
will be overhauling my reardiff as well. Hopefully it can be done over a week-end.
I assume I will not need the complete overhaul kit, just the bearings and seals for the drive shafts.
Does anybody know the TIMKEN part no. for the bearings?
Seals have part no. TZB 500050?Achim
own garage certified LR tech
Disco 2 TD5 MY 2001 - gone but still driven by another owner
Defender 110 TD5 driving me bananas with all faults
Disco 3 TDV 6 HSE MY 2005 gone @280.000 km
Disco 4 SDV 6 HSE MY 2012
1st Nov 2020 9:19 am
Sidestick
Member Since: 22 Apr 2012
Location: Rome
Posts: 2321
the Timken overhaul kit is so cheap that IMHO is a good idea to change every bearing inside the diff while it sit on a working table - Easy-Lift suspension module 4.0
- GoodWinch 9500 lb
- Full underbody protections
- Tree/Rock sidebars
- Prospeed roofrack & ladder
- Compressor guard
- Raised Air Intake
- Driving lights (2+4)
- 50 mm Waffle boards
- Altox Heater control
- Overland Rooftop Tent
- Rear seats entertainment
- Front & Rear camera
- GVIF
- Removable tow bar
- Cubby box fridge
- BFG KO2 265/65R17
- iidTool BT
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the disco is love and pain!
