Rear Disco Axle With Hole?

Hi

Ive got a 1991 Discovery 1 200tdi with a leaking rear axle, i wire brushed it to see where it was leaking from and found a tiny hole just off centre of the bottom of the pan, ive tried plating it and covering it with chemical metal, apart from having a new pan welded on, what other options are there?

Peter

You won't get chemical metal to stick unless you drain it, remove the diff and thoroughly de-grease the pan inside and out.
If you're going to go to that much trouble, you might as well fit a new diff pan.
Another option is to buy a 2nd hand axle and replace the whole thing.

do yu use it off-road?
Do yu have a diff guard, coz they are prone to making the pans rot quickly?

yu can get strengthened diff pans if yu need, rather than a pan and a guard.

I had a 1991 TDI with a rotten diff casing it reminded me one day on the A55 on the way home when it started making unpleasant noises. You havent bought one with REY on the reg plate have you.

Andy.

Treworgey 90 said:

You won't get chemical metal to stick unless you drain it, remove the diff and thoroughly de-grease the pan inside and out.

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Did all of the above thinking it was the easier/cheaper option, then realised that the diff after a couple of weeks started to leak again.

Treworgey 90 said:

If you're going to go to that much trouble, you might as well fit a new diff pan.

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Exactly what I ended up doing, a damn site quicker and a lot less hassle in the end, now all I need to do is get the rear one sorted in the new year:doh:

right i was told this wouldnt work but i had a plate on me front axle diff pan that had been bodged welded and ****ed oil out. i started by draining the diff dry, next i bought a wire brush to go on the end of a drill i then brushed and brushed and brushed, must have been 2 hours brushing, i then got some hot soapy water and SCRUBBED the shiny metal with a scourer i then got some quicksteel dipped it in warm water as i find it makes it more usable, and moulded it over the hole, i then wet my finger and smoothed the edges right out so it formed a seal. its been 4-5 months and not a drop. hope that helps

Thanks guys, in the end i wire brused it to shiny metal, removed the diff and drilled the hole out and tapped it and sealed it., but it kept leaking so after some more investigation, there is a second bigger hole. so im patching it with resin and metal plates.

lol i'v just had this problem aswell and now im replacing the pan with a new one after all the time spent tryin to fix it before i now wish i had just bought a new pan and done it that way.

My front diff pans leaks, one day I'm going to have to stop bodging patches and fit a new diff pan. What's involved in removing the half shafts?

Richard
300Tdi Automatic
Cardiff

I have the same problem appearing on my rear diff.
my local mechanic says he has done a few of these with resin, no probs.
I will be getting it done in the next few weeks, I'll take some pics of him fawking it up

you undo the bolts on the hubs and pull them out, but make sure to drain the oil first...

defender1990 said:

you undo the bolts on the hubs and pull them out, but make sure to drain the oil first...

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My problem is with my front axle, I thought there was more to it on the front

Richard Martin said:

My problem is with my front axle, I thought there was more to it on the front

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Yes, there is.
You need to remove the caliper, hub and stub axle, before you can pull the half shaft.