Discovery 2 - Air Conditioner Drains

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Originally Posted by Random88

My wife bought a 2004 D2 with 30,000 on it, very good condition and low Ks. Less than 2,000 kmx latter the front drive shaft failed, thrashed about and dinted the side of the gearbox.
The local Rover specialists said the failure was caused by the aircon drain and that it was a known problem.

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It seems the factory didn't, they had 5 years of D2 building and didn't address it at the factory.

The 30,000 was done in Cairns. I suspect that the humidity would have pumped above normal quantities of water across the uni joint, combined by the low ks and it was a recipe for corrosion. The joint rarely got to operating temperature. So we were told this joint also was not serviceable, no nipple.

Well, Only 30Ks on a 2004?

Yes! in Cairns with high humidity the aircon will drop huge amounts of water all over the DC joint and the inhibitor switch on the other side.
you were lucky the shaft only dinged the side of the gearbox rather than busting the housing.
Divert the drains as suggested here on this forum and buy a replacement greasable DC joint. Reps for Hardy Spicer or similar should be able to supply for around $300 or so,but you might need to shop around.Cairns is a big place so I think you should be able to come up with something.

Trev.

sorry,misread your post,I guess it is not up in Cairns now,anyway previous comments still valid.
Trev.

It's not in Cairns now, and the 30,000 was years ago now. It seems the factories failure to address this is well known, they are very lucky that no on was injured or killed when these failures happen. My wife had just turned a low speed corner when it happened but it could have been dangerous. Fleets have been recalled for less serious issues.
She only bought the thing because a water pump failure in the 1994 disco had ruined her confidence on towing horses with the old girl. A confidence thing. So after buying the newer version a far more spectacular failure happened!
The serviceable joint and replacement switch are in place now. I only commented to support the original posters question.

7.9mm I.D fuel hose fits snugly into the drain tubes once the nipples are removed. I used about 600mm and cable-tied it to an exhaust bracket, no probs.(I haven't bothered to replace the nipples as I do very little wading).