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View Full Version : Assembly Faults- Diff mount not tightened



multistrada
3rd October 2011, 10:35 AM
Has anyone experienced bolts/nuts not tightened during the original assembly of their D4 and coming loose in 25,000km/15 months? Also appreciate any feedback on what, if any, collateral damage may have been caused by the following tale. (D4 3.0 15 months and 25,000km old, exclusively highway and town driving)

Driving to Melb last week and had to go off the freeway into Morwell to drop off some stuff. As I slowed down there was a distinct “clunk” and a shudder through the car (nothing like the clunks that are normal and referred to in a recent thread). Rolling the throttle on and off, very gently, repeated the clearly audible noise and a shunting that could be felt – definitely something loose between the crankshaft and the Rims! This dispels the myth that Landies always break down at the most inconvenient place and furthest from Home and a Service centre - this was within 500m of the only Land Rover dealer in Gippsland (but I was time critical to catch a flight in Melbourne, so..…..)! In this short distance, the shunting and the noise became worse. About a week earlier I thought I felt a very slight version of this while driving in home town, but couldn’t reproduce it and had been watching for it.

Anyway, very short demo drive to Service Manager, up on the hoist and tighten the front mount on the rear diff which, from the Service Manager's feedback, was never tightened during assembly and had taken 25,000km (purely road driving) to work its way out from Finger tight and in the next 100km had worked to be very loose - close to falling off. Diff was rotating up and down on its other (rear) mounts. Fortunately this didn’t happen in a month’s time when I’m going into Wonnangatta (although after this experience, perhaps I’ll revert to a day trip on the KTM!)
[PS. Pat on the back to the Dealer (who I didn't originally buy from!) for fitting me in and getting me back on the road:)].

Any similar history on other recent Discos? What else has been left loose?

(and yes, this is the same D4 that was overfilled with oil and ran on:mad:, about a month ago (by a different Dealer))

cheers

CaverD3
3rd October 2011, 12:57 PM
If the diff is mounted via bushes I would be getting them to change them. But I think it is just bolted on. If the hole hasn't worn there would probably be no more issues.
Next time I would get them to go ver all the bolts on the underside; maybe the same bloke did them all.
Sounds like human error to me.