Member Since: 12 Dec 2005
Location: Sydney
Posts: 40
Discovery 3 TDV6 Front Diff question
Still have my 2004 build D3 TDV6 number 466 now with 248,000kms. Broke down the other day. Drivers side front drive shaft popped out of the front diff by enough to disengage. No warning. Only figured out later the car could move in low range rock crawl which locks the center diff.
I've had the car on the hoist and drained the front diff. Oil had its share of metal glitter in it. Is anyone prepared to guess?
a. I need a new drive shaft and a new front diff (ie something other than bearings have gone in the diff.)
b. I can get away with a drive shaft and a bearing rebuild on the front diff ( I have done the rear diff in the past )
I get limited time on the hoist so I ideally want to be prepared to have the parts to do the whole job. So love to hear from anyone who has experienced a front diff failure like thisJul 04 Build TDV6 HSE Car #466 , Reversing Camera, Front Brembos Rear V8 brakes, Allisport intercooler, D4 Bluetooth and the odd S/W upgrade courtesy of the Faultmate MSV-2
If you can get the parts then rebuild it, if the pinion wheel bearings are ok then its a straight forward job, if not then its a lot more work setting it up after.
Flack
19th Jul 2020 9:05 am
dub01s
Member Since: 12 Dec 2005
Location: Sydney
Posts: 40
Flack,
I did a complete bearing replacement on the rear diff after the internal paint failure, so I have the bearing pullers. Apart from the CV shaft and the bearings do you think is there anything that's not included in a bearing kit ie DOK007 that is to have likely to have failed?Jul 04 Build TDV6 HSE Car #466 , Reversing Camera, Front Brembos Rear V8 brakes, Allisport intercooler, D4 Bluetooth and the odd S/W upgrade courtesy of the Faultmate MSV-2
You still cant get hold of the crushable sleeve as far as I know, but if your careful you can use the old one, you just need a tube of similar size and a small hide mallet.
Flack
19th Jul 2020 8:20 pm
garrycol
Member Since: 06 Dec 2010
Location: Canberra
Posts: 1117
Given the front diffs aways have metal glitter no matter how often the oil is changed, what makes you think you actually have a problem with the diff itself?
I believe in doing the easy stuff first. Unless you have real evidence there is something wrong with the diff I would be looking at why the shaft came out - more likely wear on the shaft so look at replacing it first - is only a couple of hours in your driveway.
If then you still have an issue look at the diff - refurbished ones do come up locally online from time to time for around $1200 and second hand for about $700 but I would be weary of this option.
Garry
20th Jul 2020 2:50 am
Globetrotter448
Member Since: 21 Mar 2017
Location: Londonderry NSW
Posts: 1793
For the drive shaft to 'pop' out, means it either was not assembled correctly, without the locking clip or not fully home to lock into place.
Was the shafts changed or serviced at some time?
20th Jul 2020 11:20 am
dub01s
Member Since: 12 Dec 2005
Location: Sydney
Posts: 40
Here it is. This drive shaft was changed. But like 100k km ago. I split the diff and flushed it out. Did the upper arms while I was in there.Jul 04 Build TDV6 HSE Car #466 , Reversing Camera, Front Brembos Rear V8 brakes, Allisport intercooler, D4 Bluetooth and the odd S/W upgrade courtesy of the Faultmate MSV-2
10th Aug 2020 12:01 pm
dub01s
Member Since: 12 Dec 2005
Location: Sydney
Posts: 40
Here it is. This drive shaft was changed. But like 100k km ago. I split the diff and flushed it out.
Did the upper arms while I was in there.Jul 04 Build TDV6 HSE Car #466 , Reversing Camera, Front Brembos Rear V8 brakes, Allisport intercooler, D4 Bluetooth and the odd S/W upgrade courtesy of the Faultmate MSV-2
10th Aug 2020 12:02 pm
Globetrotter448
Member Since: 21 Mar 2017
Location: Londonderry NSW
Posts: 1793
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