Defender went bang, no drive unless in diff lock.

About to go to work,pull out the first road and bang,loose drive.
Thought it mightve gone into transfer box neutral, nope still in drive but nothing.

Put it in difflock and drives with no bangs,prop shafts both look fine,can't see anything obvious underneath.

Pulled the drive flanges and they all look fine.
Was really hoping it was just one of them.

Not sure how to test what bits gone bang now?

1986 110.

Remove plugs in axles & see/touch for any metal.

It is most likely a half shaft has gone. Start with the easy stuff and pull the rear ones to check. If good they you are in for more work at the front end

Start with the easier stuff.
Put it in gear not in diff lock and look underneath. Which prop is turning? That’s the end to start on.

Obviously do it with somebody in the cab for safety reasons.

J

Jacked up drivers side wheel, it turns but jams and knocks.
Passenger side rotates freely.
CV joint gone?
Rear shafts are fine.

Question to all: if no props turning would it be center diff? As diff lock bypasses that?

need to look at manual.

J

Prop moves if I turn passenger front but not drivers.

It'll have to wait till the weekend now to strip it down

Sounds like the drivers side CV joint.

I've orderd one of the britpart kits so hopefully I can just go ahead and get it done this weekend, assuming it is just the CV.

owas said:

I've orderd one of the britpart kits so hopefully I can just go ahead and get it done this weekend, assuming it is just the CV.

Click to expand...

Before you start, get the half shaft too. (You can return what you don't use).

Yup is the halfshaft,snapped.
Not sure how to get the rest of it out though?

owas said:

Yup is the halfshaft,snapped.
Not sure how to get the rest of it out though?

Click to expand...

Where's the break? I've not had the problem, but if it's at the outer end I'd think decent magnet and gentle wiggling of the prop or opposite wheel. Maybe take the ball off for more access. If it's the inner then it's diff out time.

Diff end unfortunately, really didn't want to have to pull the diff but yeah no chance of getting it out otherwise.
This is abit iffy on gravel..

owas said:

Yup is the halfshaft,snapped.
Not sure how to get the rest of it out though?

Click to expand...

Broom stick from the other side

Hicap phill said:

Broom stick from the other side

Click to expand...

I've never taken a diff apart, is it hollow through the middle?
Much prefer to do that that get under it right now.

There's a tool for that.
https://foundry4x4.co.uk/index.php?route=product/product&product_id=75

It may be difficult to get the diff out if there's a bit of half shaft sticking out into the axle tube, because it'll foul the axle casing. If it has snapped off right where the splines join the smooth bit of the shaft you might be lucky, but if there's anything sticking out it won't come. The diff has a shaft through the middle to mount the gear wheels on that comprise the diff mechanism, so you probably won't be able to poke anything through the middle.

I've already stripped down the other side now I was expecting to fight the caliper bolts, came straight off.

Well I can see the shaft through the middle now, but it looks like I should be able to hammer an m8 rod from the other side perhaps ...

Nope that didn't work, shaft is broken inside the diff, I don't think the magnet tool will work.

Diff out then ...

Often the sheared off stub of the shaft can be stuck in the bevel gear [ due to burrs ] Removal of diff is best as now you can remove the cross pin [ would have been in the way of your rod] and have access across the diff carrier to give stub a belt. There may be some chewed up bits of metal in the diff pan to clear out as well.

Well that was quite a dramatic failure, fell apart as I knocked it through.
Splines look good and can't see any damage inside the diff itself so I'll clean up and refit