200tdi rear diff EPIC FAIL

russ.star · Jun 5, 2016

Hi all,
So today was very good ( to start ) replaced steering bar and track rod ends on defender 110 200tdi drives lovely !

So took for a drive and BANG ! Followed by grinding coming from rear diff on close inspection the level plug has disappeared and all the thread has been pushed out.
I topped this up 2xmonths ago and there are no signs of any leak on my drive.

Any ideas why this happened was fine before no noise ?

Flossie · Jun 5, 2016

Oil wouldn't come out whilst your parked unless facing uphill, but the rotation of the diff gears would fling it out whilst driving?
It's common for the diff pan threads to fail if the plug is overtightened.
Another good s/h axle would seem the best option.

jamesmartin · Jun 5, 2016

russ.star said:
Hi all,
So today was very good ( to start ) replaced steering bar and track rod ends on defender 110 200tdi drives lovely !

So took for a drive and BANG ! Followed by grinding coming from rear diff on close inspection the level plug has disappeared and all the thread has been pushed out.
I topped this up 2xmonths ago and there are no signs of any leak on my drive.

Any ideas why this happened was fine before no noise ?

diff pin failed pushing plug out id think

Elltee · Jun 5, 2016

Breather blocked causing it to build pressure?

300bhp/ton · Jun 6, 2016

Elltee said:
Breather blocked causing it to build pressure?

I'd go with JamesMartin. Seriously you need some extreme pressure to strip the threads of a large metal level plug. Seals would have blown long before.

russ.star · Jun 6, 2016

Few pics

Brown · Jun 6, 2016

Somebody on here a few years ago described the experience of the plug on a Salisbury diff fouling on the mechanism and getting pulled in. Looks like something similar has happened to yours. There doesn't seem to be much clearance between the mechanism and the plug. Especially when it has been in and out of the pan a few times and the tapered plug gets wound back in a little further every time, as the threads loosen up.

russ.star · Jun 6, 2016

I was expecting to find some metal in the case but doesn't seem to be any.

Going to put on axle stands and remove shafts tommorow .

Thanks all and will let you know what I find. ( 2nd have axle conplete already ordered)

200tdi rear diff EPIC FAIL

russ.star

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Flossie

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jamesmartin

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Elltee

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300bhp/ton

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russ.star

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Brown

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russ.star

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