Member Since: 06 Nov 2014
Location: St. Helens
Posts: 34
Front propshaft removal and refitting questions
Front diff was diagnosed as being at fault (sounds like a washing machine barrel coming loose at speed) so thought I would give it a go to learn something and save money. Old diff out no real problems, however, front propshaft is now giving me some level of grief as I underestimated how much of a PITA the front prop is compared to the rear. I used some of the pointers but cannot find a definitive answer to removal and refitting. Anywho my questions are:
1. How easy is it to remove the propshaft from the flange in the transfer box and can I use a drift instead of a cold chisel while rotating the prop - 180 deg, then 180 then 90
2. Once out of the transfer box, and I plan to reuse it, can I just slide it to the left side out of the way to get the diff back in?
3. What is the procedure to refit the propshaft back into their prospective homes in the transfer box and front diff?
Thanks for your helpNew to modding my disco 3
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21st Aug 2024 2:06 pm
rrhool
Member Since: 28 Aug 2014
Location: Norfolk
Posts: 4538
If I remember from doing my front diff, it's easier if you take the gearbox crossmember off.Richard
D3 SE 2007. Triumph 2.5Pi 1973. Ferguson TEA20 1948.
Discovery 2 4.0 ES 2001- Gone
Discovery 1 300Tdi ES '95 - Gone
Range Rover Classic '79 - Gone
21st Aug 2024 3:03 pm
Discodancer06
Member Since: 06 Nov 2014
Location: St. Helens
Posts: 34
Im a bit apprehensive to start undoing the crossmember if the bolts are seized and the captive nuts start spinning. Is there a surefire way to stop the scenario of that? Can the gearbox support be removed instead to make a bit of space?New to modding my disco 3
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21st Aug 2024 3:25 pm
rrhool
Member Since: 28 Aug 2014
Location: Norfolk
Posts: 4538
No captive nuts IIRC, just nuts and bolts. . It's the actual crossmember that needs to be out of the way to drop the propshaft, don't think removing the gearbox mount helps much.Richard
D3 SE 2007. Triumph 2.5Pi 1973. Ferguson TEA20 1948.
Discovery 2 4.0 ES 2001- Gone
Discovery 1 300Tdi ES '95 - Gone
Range Rover Classic '79 - Gone
21st Aug 2024 3:30 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 5063
As Richard say's the answer lies in the crossmember but you don't have to take it off!
Mark the position of the joints relevant to the diff and the transfer box couplings. Use a wooden drift and a hammer to shock the joint loose but be careful here not to damage the joint.
Undo the transmission mount bolt and then remove the passenger side crossmember bolts only! Use a large pry bar to pull the crossmember down on that side and you'll have enough clearance to slide the shaft out rearwards.
Realign the prop with the marks you made earlier, then reassemble using new coupling bolts only as there is a high likelihood they will snap yµ (idµ - eAµ) ψ=mψ
21st Aug 2024 4:33 pm
Discodancer06
Member Since: 06 Nov 2014
Location: St. Helens
Posts: 34
Thank you
Next question - once off, how can I reinstall to the transfer box and diff? Is it tapped back into place?New to modding my disco 3
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23rd Aug 2024 11:18 am
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 5063
You don't need to remove the transfer box, just the bolt through crossmember mount. The diff is just raised back into position!
The crossmember will be stiff so a large pry bar is needed,(eg steel tubing) but it can be helped if you can loosen the drivers side crossmember bolts a little. The tank guard fouls this but it's doable.yµ (idµ - eAµ) ψ=mψ
23rd Aug 2024 1:27 pm
Discodancer06
Member Since: 06 Nov 2014
Location: St. Helens
Posts: 34
So front prop is off, used a chisel in the end. Now battling with reinstalling it, I'm at my wits end
How does it go back in?New to modding my disco 3
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27th Aug 2024 3:21 pm
Pete K
Member Since: 15 Jan 2016
Location: GL
Posts: 10735
one you have to old one out, it's all down hill now.
27th Aug 2024 3:29 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 5063
Discodancer06 wrote:
So front prop is off, used a chisel in the end. Now battling with reinstalling it, I'm at my wits end
How does it go back in?
It's a reversal of the removal procedure and the challenging bit will be re-torqueing the drive shaft bolts if you're doing it on your back. Remember, new shaft bolts only and get an assistant if possible to help stop the shaft from rotating. A square shaft pry bar is useful when placed between two bolt heads to stop rotation!yµ (idµ - eAµ) ψ=mψ
27th Aug 2024 4:55 pm
Discodancer06
Member Since: 06 Nov 2014
Location: St. Helens
Posts: 34
The end of the propshaft (the diff end) came off, I've tried to put it back but it doesn't seem to retract the same as the other end. Is it better to get a new front prop rather than trying to fix the old one?New to modding my disco 3
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27th Aug 2024 5:26 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 5063
Are you saying the joint has fallen apart?yµ (idµ - eAµ) ψ=mψ
27th Aug 2024 5:28 pm
Discodancer06
Member Since: 06 Nov 2014
Location: St. Helens
Posts: 34
Not completely, can it be repaired or am I looking at a new front prop?New to modding my disco 3
Added the forum badges front, back and one side so far
27th Aug 2024 6:31 pm
PROFSR G
Member Since: 06 Mar 2017
Location: Lost
Posts: 5063
Yeah you need to be careful when separating the joint but it can usually be put back, it's just messy.
A lot cheaper than a new shaft which will set you back £200+ minimum for a cheap one.yµ (idµ - eAµ) ψ=mψ
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