Disco 2 Blown a hole in front diff

Evening ladies and gents.
Just landed home on the back of a truck.
Thought transfer box had gone, on closer inspection, oil everywhere and a 10p sized hole in my front diff.

Anybody know why this would happen?
Got some pictures will add soon.

Had similar, in the rear diff on my 90.

iirc one of the bolts on the crown wheel came loose and punched a nice hole in the diff cover.

welded it up, changed diff to a second hand one, replaced oil. Job done.

Hope it is as smooth on yours.

Cheers

neilly said:

Had similar, in the rear diff on my 90.

iirc one of the bolts on the crown wheel came loose and punched a nice hole in the diff cover.

welded it up, changed diff to a second hand one, replaced oil. Job done.

Hope it is as smooth on yours.

Cheers

Click to expand...

Fingers crossed, hopefully going to try and source a diff/axle tomorrow and get back on the road.

Here's a pic

KyleAsh91 said:

Fingers crossed, hopefully going to try and source a diff/axle tomorrow and get back on the road.

Here's a pic

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That's a very neatly punched hole, make sure you let us all know what the cause was. I'd be most interested.

Gazbo said:

That's a very neatly punched hole, make sure you let us all know what the cause was. I'd be most interested.

Click to expand...

Will do, I'm intrigued myself. Safe to say whatever it was it wanted out!

KyleAsh91 said:

Will do, I'm intrigued myself. Safe to say whatever it was it wanted out!

Click to expand...

Usually the axle pin for the planetary gears but that scoops a big gash, yours looks like it was done with a punch and die set, v neat.

This is what i found in mine,

Made an effort, but the whole punched was not big enough. Looks like someone rebuilt it in the past but did not torque it up correctly.

Cheers

neilly said:

This is what i found in mine,

Made an effort, but the whole punched was not big enough. Looks like someone rebuilt it in the past but did not torque it up correctly.

CheersView attachment 113645 View attachment 113646 View attachment 113646

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Looks like a good effort!
Will get some pictures of mine later today or tomorrow, managed to source an axle locally going to pick it up shortly. So once I've got the fresh one on ill pull the old one to pieces and assess the damage.

That's the remains of the diff.
New axle on but it all feels a bit stiff. Got some sort of ABS fault now also but perhaps I've damaged an ABS sensor in the process. At least the thing drives now!

KyleAsh91 said:

That's the remains of the diff.

Click to expand...

Yep, that'll do it every time, so It was the "usual suspect" after all.