Disco 2 Front Differential Replacement

Hey all,

Another question! My front differential is on the way out unfortunately, along with the half shafts too - this is after just having both front wheel hubs replaced, so been an expensive month or two...

So, I'm going to source a second hand diff from the great bay, along with hopefully some shafts (did think about buying brand new heavy duty upgrades, but waaayyy too much money!)

However, I've never replaced a diff before! Had a search and couldn't find anything, was wondering if anyone knows of a good guide? Any tips - tools required that might not be obvious, any seals/other bits I should replace at the same time?

Cheers,
Stephen

diff is held in by 10 9/16 socket sized nuts, you can use 14mm but sometimes its a bit tight on the nuts, you need to drain oil first and half shafts pulled out, which you could have done when you had wheel hubs off, so they need to come off again, if any seal isnt leaking dont replace you might well create another issue, get a can of brake clean to clean mating surfaces and an oil resistant silicone sealant for refitting diff, to remove track rod undo nut and using a large hammer crack end of swivel steering arm till joint taper is released

Hi jamesmartin,

Thanks for that, really helpful! Yeah I got the garage to do the hubs, as they thought that's all the problem was - then they've now said it's the diff. Okay, good advice on the seals - what's the recommended oil for in the diffs?

Cheers,
Stephen

HavoK said:

what's the recommended oil for in the diffs?

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multi-gear 75W90 any brand you want even though the recommended one is Texaco 75W90R

75W/90R

brian47 said:

75W/90R

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The "R" is specific only for texaco which might be hard to find but IMO for the diffs any 75W90 GL4/5 is good

HavoK,

I'm breaking a D2 if you want the front axle.
Not sure how to PM you but contact me if you want parts.

James

Hi @jamesmartin,

Sorry to sound like a complete idiot, when you say "oil resistant silicone sealant" can you recommend anything? There's so many types...would the Loctite SI 5990 be the right stuff?

Just ordered some Loctite 248 (the stick stuff) to go on the bolts, hopefully got that right...

Picking up a torque wrench and oil over the weekend too, hopefully get this done next week at some point!

Thanks again,
Stephen

HavoK said:

Hi @jamesmartin,

Sorry to sound like a complete idiot, when you say "oil resistant silicone sealant" can you recommend anything? There's so many types...would the Loctite SI 5990 be the right stuff?

Just ordered some Loctite 248 (the stick stuff) to go on the bolts, hopefully got that right...

Picking up a torque wrench and oil over the weekend too, hopefully get this done next week at some point!

Thanks again,
Stephen

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it would do but si 5980 would be better

Great, will get that then! Cheers!

(Also I probably be back, approximately halfway through doing the job, when it goes wrong asking for more help haha!)

Thanks so much,
Stephen

Started taking it apart over the weekend, gone fairly smoothly, (hopefully haven't just jinxed it!) however whilst it's all in pieces it makes sense to get some other jobs done, so, questions:

Paint - I had previously stripped and painted a lot of the chassis with Hammerite, however it's already coming off so don't want to use that again. The front axle isn't too bad rust wise, but would still like to give it some protection/a bit of a spruce up - so any tips/recommendations? How much do I need to rub down, if I don't have to go back to the metal that would be preferable haha.
Calipers - any tips on cleaning those before painting?
Anything else anyone would recommend checking/sorting/getting done whilst I'm there? I'm going to get extended axle breathers, with new little plug things to go in the axle, as I think thats where the water got in, and hoping to fitt a diff guard too, but just wondered if there was anything else!

Thanks,
Stephen

Got it out! Besides the oil looking a funny colour, I couldn't really see anything physically wrong with the diff...drive shaft ends don't look worn either...

Has this all been for nothing?? (The garage said it was my diff that was causing the horrendous clunking/grinding noise) there was quite a bit of metal filings when I drained the oil, but apart from that I can't see anything wrong - anything I should be looking for? Or what else could the issue have been?

Cheers,
Stephen

All done! And it drives

However, the original issue and reason for replacing the diff has not been completely cured...it's a lot better but still there. And looking at the state of my old diff, maybe that wasn't even the issue (although the metal filings and colour of the oil definitely weren't good), so perhaps the garage told me wrong.

Basically, I get a horrible grinding/clunking noise when de-cellerating - not braking, just slowing down, with foot coming off the throttle. Noticeable at all speeds it seems, and now there's also vibrations at around 45mph that sounds horrible. What could be the cause? Oh also - I noticed that if I pop it into neutral when slowing down then the noise stops...

And on another note, it pulls to the right when braking hard?

The problems seem to be never ending!

Cheers,
Stephen

rear diff or t/box ,or even gear box without looking at the vehicle its difficult to say you need to check each for signs of issues, oil and play

jamesmartin said:

rear diff or t/box ,or even gear box without looking at the vehicle its difficult to say you need to check each for signs of issues, oil and play

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Interesting - forgot to mention it does sound/feel like it's coming from the front though, so hopefully not the rear diff! What exactly am I looking for (sorry bit of a novice when it comes to this stuff). From the outside, I couldn't really see any leaks or anything?

Thanks,
Stephen

HavoK said:

All done! And it drives

However, the original issue and reason for replacing the diff has not been completely cured...it's a lot better but still there. And looking at the state of my old diff, maybe that wasn't even the issue (although the metal filings and colour of the oil definitely weren't good), so perhaps the garage told me wrong.

Basically, I get a horrible grinding/clunking noise when de-cellerating - not braking, just slowing down, with foot coming off the throttle. Noticeable at all speeds it seems, and now there's also vibrations at around 45mph that sounds horrible. What could be the cause? Oh also - I noticed that if I pop it into neutral when slowing down then the noise stops...

And on another note, it pulls to the right when braking hard?

The problems seem to be never ending!

Cheers,
Stephen

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Mine was doing the same thing. I changed the oil in the gearbox and this sorted it.

HavoK said:

Interesting - forgot to mention it does sound/feel like it's coming from the front though, so hopefully not the rear diff! What exactly am I looking for (sorry bit of a novice when it comes to this stuff). From the outside, I couldn't really see any leaks or anything?

Thanks,
Stephen

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Have you checked the cardon joints on the front propshaft? You could get similar symptoms from them being worn