Dave Smith's Freelander

From photo that is seized. If the easy out snaps you are truly fubarred!!!

davidsmith1307 said:

Spare time today so I fitted my MuddyMods clutch slave bracket to replace the bendy, rusty thing that was there.
Time to attack the rear diff. Absolutely no joy getting the oil seals out - really hard to hold the diff when it is out of the car.
Thought I'd swap the mounts. Side ones no real problem.
'Slight' issue with the lower bolt on the front one....
View attachment 208690
Not sure what I'm going to do about that.

Click to expand...

Take the input flange off the diff, will make it easier to get the drill square to the bolt.For the diff seasl, carefully hammer in a small screwdriver between the seal and the diff body, then lever it towards the centre, then remove the small one and use two bigger screwdrivers towalk around it and rip the seals out, the new ones need gently chaped in with a mandrel such as a suitably sized socket.

andyfreelandy said:

The problem is the drill would much rather drill the Ali than the steel!! Centre mark bolt and pilot drill. Use a cobalt drill bit then increase to size gradually. Good luck!!

Click to expand...

This ^^^ exactly.

Centre punch the broken bolt first. Then use a 3mm Cobalt drill with plenty of oil, withdrawing the drill regularly to clear the chips. Move up to a 4mm Cobalt drill, then a 5 and 6, before using the correct size (6.8mm for an M8) to tap the thread.

Nodge68 said:

This ^^^ exactly.

Centre punch the broken bolt first. Then use a 3mm Cobalt drill with plenty of oil, withdrawing the drill regularly to clear the chips. Move up to a 4mm Cobalt drill, then a 5 and 6, before using the correct size (6.8mm for an M8) to tap the thread.

Click to expand...

If it wonders slightly and you end up with an ovaloid hole, don't worry, its not the absolute end of the world, you won't need a new diff, there is enough clearace at the back to put a nut and bolt in, or you could enlarge the hole to m10 and retap it.

Looking at the two sheared ends of the bolt show that the bolt has largely been cracked through for ages.

Got the seals out today. They were pretty well glued in with sealant. Took abuse with a claw hammer but I won.
Waiting for a socket to get the diff flange off.