200tdi broken cross shaft

hi there everyone,

I'm having some differential problems with my 200tdi discovery. the front diff suddenly started making a strange clunking noise one afternoon and continued all the way home every time i accelerated past 2nd gear. iv since removed the diff to find the cross shaft between the inner spider gears broken.

the shaft is only broken about an inch from the end and the gears are still held in place. iv removed the small circlips in order to extract the shaft for replacement but i cant seem to get it out and im a little worried about bashing it with a hammer too hard in case i break something else.

am i doing this wrong? is there a way the pin needs to be lined up to come out or do i just hammer away?

advice would be greatly appreciated! thanks

you will need to remove crown wheel first, mark crown wheel and carrier so that it goes back in same place ,it can alter run out of crownwheel

forgot to mention that the diff is completely assembled as it came out of the axle. is there no way of doing it without removing the diff from its casing? after removing the crownwheel do i then just hammer it through still?

no ,it should push/slide out unless damaged,

well the shaft is broken on one side and rotates with the gears when they turn but will not budge out of the casing even after hammering it quite hard. should the shaft be turning with one of the gears like it is?

the shaft has some flattened edges on either end and looks as tho it might need to be lined up with something?

no obviously gear is seized to shaft ,theres no lining up its as they are its buggered as diff carrier maybe to

right.. hit it harder then? or take to machine shop to press it out?

have you removed crown wheel ?

yes i have removed the crownwheel. been trying to use the new shaft ive got hammer out the old broken one. still no movement. very lost here

shaft friction welded to case or mushroomed ?

i dont believe its mushroomed but i also dont think its welded to the case because it rotates with the gear.

tis welded to gear then

great. any idea on how shall i proceed from here?

is diff carrier worn on shaft holes if so just scrap it ,if not your going to struggle to get it out ,shaft would need grinding or burning to cut it ,when you refit crown wheel you sit it in diff housing with bearings without pinion with housing stood on its nose and measure runout of rear face of crownwheel

is drilling it out worth a try?

not with a std drill its very hard , how hard have you tried knocking it out ,with carrier well supported and convex side of gear against carrier as it would run so you dont damage carrier very big hammer or press