Disco 2 Rear diff pinion seal

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Ok then! That cheers me up a bit!
Getting the diff out is easy. Halfshafts out a bit, drain oil out, undo all the bolts around the diff flange where it joins the casing and simply pull it out.
Then use whatever technique you can to separate the spigot from the diff.
Centre bolt out, big breaker bar and summat long wedged into the bolt holes of the three leged flange to hold it. I used bolts and a very long pry bar.
Change seal.
Replace centre bolt as per ^. Big torque, can't remember how much but it is in Haynes or Rave.
Replace spigot
clean up diff and axle case flanges, new seal, diff back in and bolted up.
New seals on halfshafts, if necessary, then put em back in carefully to not damage anything where they enter the diff.
Refill with oil.
Then do whatever you want to do with the prop shaft if you are not happy with the old one.
If I've missed something out, or made a mistake, as I am writing this purely from memory, then someone else who does 5 a week will jump on and point out my errors or omissions.
Anyway, best of luck.
Stan
 
Matt2e0fgx said:
I have found the flange but not sure on the prop under discovery 2 no rear prop option with rear uj listed . I'm expecting it's going to be one off a defender but it's just finding out correct length etc
Click to expand...
It’s possibly U will be out of luck, even the V8 engined D2 has the “donut” arrangement, unlike the V8 D1 that doesn’t so just like the earlier discos.
 
What a shame! Remind me, what was the reasoning behind the rubber donut? to protect the diff from shocks from the transmission or something?
 
Matt2e0fgx said:
I have found the flange but not sure on the prop under discovery 2 no rear prop option with rear uj listed . I'm expecting it's going to be one off a defender but it's just finding out correct length etc
Click to expand...
defender wouldnt be the right length, a 200tdi disco 1 would likely
 
Stanleysteamer said:
Ok then! That cheers me up a bit!
Getting the diff out is easy. Halfshafts out a bit, drain oil out, undo all the bolts around the diff flange where it joins the casing and simply pull it out.
Then use whatever technique you can to separate the spigot from the diff.
Centre bolt out, big breaker bar and summat long wedged into the bolt holes of the three leged flange to hold it. I used bolts and a very long pry bar.
Change seal.
Replace centre bolt as per ^. Big torque, can't remember how much but it is in Haynes or Rave.
Replace spigot
clean up diff and axle case flanges, new seal, diff back in and bolted up.
New seals on halfshafts, if necessary, then put em back in carefully to not damage anything where they enter the diff.
Refill with oil.
Then do whatever you want to do with the prop shaft if you are not happy with the old one.
If I've missed something out, or made a mistake, as I am writing this purely from memory, then someone else who does 5 a week will jump on and point out my errors or omissions.
Anyway, best of luck.
Stan
Click to expand...
 
I found where I can get a 200tdi rear prop and the flange kit from padocks, do I need a spacer between the flange and the uj ?

Cheers
 
Stanleysteamer said:
If I've missed something out, or made a mistake, as I am writing this purely from memory, then someone else who does 5 a week will jump on and point out my errors or omissions.
Click to expand...

Sounds right to me. Couple of additional observations. Because you only need to move the half shafts a bit, you do not need to take the hubs off, just unbolt from the axle. There is no gasket, so before you put the diff in an bolt it down, use RTV around the flange. Ideally have someone help you lift it or use a gearbox jack, it is pretty heavy for delicate manoeuvering.
 
I am also in the same situation with the removal of the spigot. I would also need to change the seal and the first attempt has failed (diff in on the car and tried to use big socket-M8 bolt method). I will give it one more try and after either by a tool what I have found on the net (https://fourby.co.uk/puller) or drill to M10 .... (or just keep topping up the oil;))
 
Si Click said:
Sounds right to me. Couple of additional observations. Because you only need to move the half shafts a bit, you do not need to take the hubs off, just unbolt from the axle. There is no gasket, so before you put the diff in an bolt it down, use RTV around the flange. Ideally have someone help you lift it or use a gearbox jack, it is pretty heavy for delicate manoeuvering.
Click to expand...
Stanleysteamer said:
Halfshafts out a bit,
Click to expand...
This is what I meant, but you have clarified it well for someone who hasn't done it before.
As for the gasket, here is a picture of the spare gasket I have left over, as I ordered two in case of accidents! You can still see the red biro with x2 on it. Dunno if mine being a 300tdi made a difference! Much easier to put this on with a load of grease to seal it but if I'm wrong and there isn't one then +1 to Si's remark. It is a heavy lump to be fiddling around with.
IMG_6067.JPG

Big :oops::oops::oops::oops::oops:!!!
Just noticed this poster has a TD5, for some reason thought he was on about a Tdi! My bad! and I wasted all that time finding the gasket.:rolleyes::rolleyes::rolleyes:
:):):):):)
Quick tip about sliding the halfshafts back a bit. Undo the bolts a tiny bit, then bang the inner ends of each bolt to free the hub and half shaft off from the hub carrier/end of axle casing, obviously with some protection to the thread ends. This'll avoid you needing a hub puller. Did this on both ends when I had to change the two hubs last year. (Glad I'm on the right Disco now!!!)
 
Last edited:
I have tried with this, does not move. The 5mm thick plate is bending.
I will give it a try with slide hammer tomorrow.
 

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berg450 said:
I have tried with this, does not move. The 5mm thick plate is bending.
I will give it a try with slide hammer tomorrow.
Click to expand...
Yes, 5mm is not thick enough especially as it does not cover the whole of the cylindrical thing you are using, but do not hold out any hope of the slide hammer working.
It IS a sod of a job and no mistake.
 
Finally i could remove it by using the big socket method! I have added one more big washer, oil between washers and big force. Important also to use high tensile screw.
 
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