Leaky rear diff pan.

This site contains affiliate links for which LandyZone may be compensated if you make a purchase.
C

chris46

New Member
Posts
18
Hi,

I need to fix my Discovery's leaky rear diff pan and was hoping to get some pointers.
I was hoping to repair it without having to drop the axle because I have injured my spine and leg falling down a bloody manhole of all things.
I am after a fix that will last until the summer when I should be more mobile and the weather's better.
Also is it possible to fit a new pan without dropping the axle and when fitting do I need to remove the old one or does the new one fit over it? Can I stick weld it? .
Thank you in advance.
 
remove halfshafts.
remove diff
wash inside & outside of pan with petrol
fill hole both sides with metal mastic (Like a rivet)
leave 24 hours
rebuild
refill with oil
use


welding a new one is very fiddly due to cast pan housing. heat transfer doesnt make welding easy.
 
Thank you. I will have a go at it tomorrow and maybe try patching the holes with metal plate. If I make it worse I only live 10 miles from Famous Four in Louth and I have been told its not that expensive to have a new one fitted. I once fixed a petrol filler neck with Chem metal and it lasted for years never leaking again.
May I also ask if a knackered front diff would only whine under load when the power is on? .it is whinning and it sounds like its from the front diff not the gearbox.
Thanks again
 
chris46 said:
Thank you. I will have a go at it tomorrow and maybe try patching the holes with metal plate. If I make it worse I only live 10 miles from Famous Four in Louth and I have been told its not that expensive to have a new one fitted. I once fixed a petrol filler neck with Chem metal and it lasted for years never leaking again.
May I also ask if a knackered front diff would only whine under load when the power is on? .it is whinning and it sounds like its from the front diff not the gearbox.
Thanks again
Click to expand...

its most common for diff to whine on over run,remove front prop and take it for a run in diff lock ,it might be simpler to give danny at amazon a ring for a price on another case
 
I used chemical metal on mine.it worked really well but make sure you clean it with a grinding disc.or sanding disc.
 
jamesmartin said:
it would be interesting to see if axle is still straight after all that
Click to expand...

Should be. Most of the welding was done on the bench.

I tacked it all up on the axle then removed it to do most of the welds on the pan. Then welded round the outside to the axle itself. Even then only layed a small weld at opposite sides and left it to cool for a while before i welded a bit more.

I'll do another soon and take plenty of measurements to see if it does warp the axle at all with my method.
 
robbh said:
Should be. Most of the welding was done on the bench.

I tacked it all up on the axle then removed it to do most of the welds on the pan. Then welded round the outside to the axle itself. Even then only layed a small weld at opposite sides and left it to cool for a while before i welded a bit more.

I'll do another soon and take plenty of measurements to see if it does warp the axle at all with my method.
Click to expand...

its all on one side you cant even up the warping
 
You must log in or register to reply here.

Similar threads

mad85
Disco 2 3.5 vs 3.54 diff ratios
Replies
11
Views
1K
mad85
mad85
H
Diso1 Diff lock how it works
2
Replies
21
Views
2K
marjon
marjon
M
How far to push half shafts into diff?
Replies
2
Views
565
mcbrl
M
M
Nightmare trying to fill rear diff with oil - Discovery 4 TDV6 2010 Auto.
Replies
7
Views
575
gemsdad
gemsdad
SteveG4TRA
ACE system pipe corrosion
2
Replies
23
Views
1K
SteveG4TRA
SteveG4TRA
Back
Top