300tdi rear diff swap

andymach23 · Oct 9, 2014

Hi Everyone.

I have a 2nd hand rear diff ready to fit and was having a look around for a fitting guide on-line. Could anyone point one out?

Am I right in thinking that I have to take the half shafts out to free the diff?

Cheers, Andy

Mark L · Oct 9, 2014

Yes.

Drain diff oil (check you can remove filler plug ok first), remove half shafts, remove rear prop at the diff end, remove all diff bolts.
Diff will then come away from axle (heavy job if on your back on the floor).
Clean mating face of new diff and axle casing, fit a gasket of your choice (I used paper), offer diff back up to casing and bolt down, slide half shafts back in, connect prop back up, fill diff with oil.

JFD.

DiscoPol · Oct 9, 2014

Mark L said:
Yes.

Drain diff oil (check you can remove filler plug ok first), remove half shafts, remove rear prop at the diff end, remove all diff bolts.
Diff will then come away from axle (heavy job if on your back on the floor).
Clean mating face of new diff and axle casing, fit a gasket of your choice (I used paper), offer diff back up to casing and bolt down, slide half shafts back in, connect prop back up, fill diff with oil.

JFD.

excellent instructions, but dont forget to chock the front wheels as once that prop is off the handbrake doesnt work any more.

Mark L · Oct 9, 2014

DiscoPol said:
excellent instructions, but dont forget to chock the front wheels as once that prop is off the handbrake doesnt work any more.

Ah yes, forgot that important detail.

Think it's 'cos mine always sits on a level, gravel surface with the handbrake forever left off.

ronsealdeath · Oct 9, 2014

I used a trolley jack to lift new one in place cos im a weakling.

DiscoPol · Oct 9, 2014

ronsealdeath said:
I used a trolley jack to lift new one in place cos im a weakling.

Puff.!!

So do I

andymach23 · Oct 10, 2014

Thanks for the info. Seems handy enough then. Would RTV sealant be suitable instead of a gasket?
Cheers, Andy

DiscoPol · Oct 10, 2014

andymach23 said:
Thanks for the info. Seems handy enough then. Would RTV sealant be suitable instead of a gasket?
Cheers, Andy

Definitely, I always use rtv now, it's a bit more forgiving than the paper gaskets imo just make sure both surfaces are clean and degreased before applying the stuff.

andymach23 · Oct 10, 2014

Brilliant. Thanks a lot.

Let battle commence

TheMunster · Oct 10, 2014

And run the sealant on the inside of the bolt holes!

And yeah trolly jack trick is best way to do it

300tdi rear diff swap

andymach23

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Mark L

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DiscoPol

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Mark L

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ronsealdeath

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DiscoPol

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andymach23

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DiscoPol

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andymach23

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TheMunster

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