Steering box and bent axle vows 2001 TD5

After a very long and high jump I did back in 2004 my Defender front wheels became severely negative cambered and then it broke the front crown and pinion in 2006 for no apparent reason and then another front crown and pinion in 2010, so now I like to think that its gonna keep doing that ever couple of years and the reason is that jump could it be the reason??

So I was thinking of replacing the whole front axle instead of just the diff so that I can get done and over with it once and for all. I reckon the front tube is bent and the camber can't be corrected any other way... is that correct? The car drives perfectly fine otherwise and the diff just broke both the times, without any warnings.
Defender parts are scare where I live but Disco 1 parts are rare but available so my question is would a front axle from a 94-97 300 TDI Disco 1 fit my Defender? Are they the same width wise or do Discos have a wider track? Last time when I replaced the diff I got one from a 96 300 TDI disco and it works fine and it has the same ratios... but I am not sure about the whole front axle.

Secondly,
I parked my car the other day and came back after two hours and saw a large puddle of power steering fluid on the floor, leaking from the steering box... what am I looking at? Are there any serviceable parts in the box which need to be replaced after some time or am I in for a new box?

Cheers!

it is the same, bar calipers and wheel bearing spacer and nut

jamesmartin said:

it is the same, bar calipers and wheel bearing spacer and nut

Click to expand...

So is everything the same?? What about the bar calipers wheel bearing spacer and nut?

James at the risk of hijacking this thread, are you saying the diffs from a 2000ish td5 90 would fit snugly into my 1995 disco 300tdi? and all be well?


please please say yes, i have had a very nice offer from a ginger man and i want to say yes

i fitted a td5 diff into my 300tdi axle there same 24spline

Raider td5 said:

So is everything the same?? What about the bar calipers wheel bearing spacer and nut?

Click to expand...

disco calipers are different but both types fit on the same and use the same bolts, whel bearings are the same but td5 uses a specific lenght spacer between bearings and one nut ,locked up tight ,300 you adjust with one nut and lock with the other

I know the diffs are the same... Are the axle the same as well or what??>

DiscoPol said:

James at the risk of hijacking this thread, are you saying the diffs from a 2000ish td5 90 would fit snugly into my 1995 disco 300tdi? and all be well?


please please say yes, i have had a very nice offer from a ginger man and i want to say yes

Click to expand...

yes but later diffs have the same lenght axle case stud (10 long)earlier uses 6 long and 4 short ,studs jut tap in/ out

jamesmartin said:

disco calipers are different but both types fit on the same and use the same bolts, whel bearings are the same but td5 uses a specific lenght spacer between bearings and one nut ,locked up tight ,300 you adjust with one nut and lock with the other

Click to expand...

So then I can use my existing uprights (bearing hub assemblies) on the disco axle?

And what about the steering issue I have? Do I need a repair kit of some sort to fix that?

if leak is from bottom of box out of shaft ,remove drop arm (pullers and large punch like a short half shaft and big hammer to hit the side of arm around shaft ),remove mud seal ,and circlip ,put a bowl under box and with engine running turn in lock it should blow steel backing ring and seal out clean shaft and box you may need some 400 grit emery or similar,aerosol brake clean is handy fit kit stc2848

Right... is there any other place in the box from where oil can leak? The car is at my and I will have to go there to check but I'm sure its from the box.

Secondly my Defender is Left hand drive so is the part number stc2848 valid for LHD vehicles too?

Thanks.

lower shaft seal kit fits all ,they can leak out of top cap and input shaft ,bottom of sector shaft is common as it gets dirty and shaft flexis when turning wheels

Right thanks!
I will get my mechanic to have a look at it just to make sure.

Secondly,
Do the 300TDI Defenders and the TD5s have the same steering box? Here in Pakistan we have RHD cars a Defender assembly plant for the military and the local market, we had the 300 TDIs till 2006 and the Puma 2007 onwards the TD5 was never launched here officially so parts are not available. Mine is an import from Dubai and thats why its an LHD. If the 300s and the TD5s have the same steering than I will be able to buy parts from here otherwise will have to get from Dubai.

steering parts are different between 300 tdi and td5

jamesmartin said:

steering parts are different between 300 tdi and td5

Click to expand...

Right Thanks...

If you have access to the parts catalog, can you please give me part numbers of all the kits/parts that can cause this leak in a steering box? I will check price and availability in Dubai and get all of them if they are cheap so that I don't get any surprises when I actually get the job done, and my brother is visiting me from Dubai anyways so it will be convenient.
Its a 2001 Defender TD5 110 Doka. Left Hand Drive.

google stc2847

I will order this kit.
And are there any other serviceable parts in the box that wear out gradually and need to be replaced? My steering is fine but I do have 115000 kms on the clock from new and I reckon this would be a good time to replace things in the steering which would fail in near future. I heard there is a ball joint or drop arm or something that wears out and gets ply in it?

I really appreciate your help!

drop arm ball joint stc3295 ,hardest bit apart from removing drop arm (though the joint can be done on the vehicle)is top race ,tool helps http://www.google.co.uk/url?sa=t&rc...iGE-uu1zFNPpTolhQ&sig2=lqg-tXo937HiiLUtXRsFfA
http://www.google.co.uk/url?sa=t&rc...HhqQ5Q_ccwTB-fx_w&sig2=7oqD0PQqhejKTFoXBn8udA

Noted!

So that's all there is that might need replacing?

seal kit and setting is really all you can do cost effectively .repcaement of box is other option