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Thread: Rear Diff Broken

  1. #1
    Join Date
    Jun 2010
    Location
    Exeter, Southern Highlands NSW
    Posts
    57

    Rear Diff Broken

    Hi all,
    Iíve got my head around putting my gearbox back together, so whilst waiting for replacement parts, I decided to strip the rear axle.
    All went well, and on inspection of the rear diff, I initially thought everything looked good, however the carrier has sheared where one of the side bearings sits. I never drove this car, but it seems the half shaft was keeping everything somewhat lined up.
    The axle casing has a large dent, where Iím guessing in the past a more substantial diff failure has caused the casing damage.
    I noticed i can get a new carrier, but Iím not sure Iím equipped to fiddle with the diff centre...Iím tempted to search for an entire rear axle with diff.
    Iím in NSW Southern Highlands. Can anyone advise if Landrover Heaven sells used parts? or if someone has swapped over a carrier on their diff, could you advise on the difficulty.

    Thanks guys!
    Marcus
    Marcus

    2014 Defender SWB
    1959 Series II Ute

  2. #2
    Join Date
    Apr 2019
    Location
    South Australia
    Posts
    148
    If you can do the gear box then the diff shouldnít be a big challenge. The manual is excellent for giving the tolerance and there are some good you tube vids.

    I had a bad diff on Sid and bought a Ďmintí new axle only to find a cooked bearing so had to rebuild anyway.

    I did document the diff rebuild in my thread

  3. #3
    Join Date
    Jul 2018
    Location
    Northshore, Auckland NZ
    Posts
    10
    I just rebuilt my diffs on my s3 109 with new r+p, new truetrac carriers, and new bearings. Definitely possible for the backyard mechanic if you're willing to do the reading and understand the process. You need a dial guage, vernier calipers and a torque wrench.

    If it's a rover diff then fitting a new carrier is pretty simple, as you adjust the backlash with threaded adjusters, and you can work on it on a bench (or the tray of your ute). Salisbury is harder as you have to use shims to set preload and backlash, and you're installing it and checking lying under the truck.

    If the carrier's flogged out then consider that the pinion bearings might need replacing too. If they're in good condition then there should be some resistance/drag to turning the pinion. My Salisbury appeared to be working fine, though the pinion preload was about 0. When I stripped it the carrier bearings were pretty rooted with massive pitting on the races, and the pinion bearings had very obvious visual wear.
    1975 S3 Ute with Toyota 13bt, H55f + transfer, Holset he221w turbo.

  4. #4
    Join Date
    Jun 2010
    Location
    Exeter, Southern Highlands NSW
    Posts
    57
    Ok, thanks guys.

    Cadas, Iíve been using your excellent thread for most of my gearbox rebuild! Will keep going on to the diff.

    NZ Nath, I have those tools...I donít have a press (but do have access to one) and I watched a couple of videos and started glazing over when they talked about pinion height setting blocks and dummy bearings etc 🤯.

    Thanks for the confidence! Iíll read a bit more. Probably more questions to come!
    Marcus

    2014 Defender SWB
    1959 Series II Ute

  5. #5
    Join Date
    Apr 2019
    Location
    South Australia
    Posts
    148
    Did the diff before the gear box.

    Thereís a couple of extra tools, a set of fishing scales to measure the rotational drag when setting the backlash and a shop made tool to tighten the carrier nuts. The tool is worth making as it is needed for torquing up the gear box flanges.

    Just a flat steel bar with holes drilled for two bolts.

    The only thing that can be tricky to get are a set of shims if you replace the pinion bearing. think you can buy packs or find a handful of second hand ones as you need a few, itís trial and error . I had spare broken diffs.

  6. #6
    Join Date
    Jan 1970
    Location
    Central West NSW
    Posts
    24,351
    In my position I would simply fit another complete differential into the axle housing. Good second hand diffs should be readily available, although shipping them would be more expensive than just shipping parts. But then I have a number of "spare" 2as to get parts from!

    The only real caution if going this route is to check that both your vehicle and the one you are getting are the same ratio. If yours is standard (4.7:1), while there were numerous changes, the differentials are interchangeable from about 1949 to the end of Series production (but some models had different ratios e.g. V8 & Isuzu) a very few had completely different diffs (One Ton and Series 2b FC) and the salisbury rear axle was optional on 109s at the end of 2a production and standard on S3 109s. And note that while front and rear diffs are interchangeable late model front diffs lack the filler plug in the nose.
    John

    JDNSW
    1986 110 County 3.9 diesel
    1970 2a 109 2.25 petrol

  7. #7
    Join Date
    Jul 2018
    Location
    Northshore, Auckland NZ
    Posts
    10
    The dummy bearings are only really needed for the carrier on the Salisbury. Even though my old bearings were worn I sanded the inner races with a flap wheel and used them as dummies, and the final install with new bearings resulted in the same backlash and similar preload (as measured by whacks with a hammer to install).

    The pinion height is set with shims behind the outer race on both diffs, and that isn't too hard to knock in and out to adjust. I made a stab at setting pinion height using the vernier and dial guage, but it's hard to do accurately without the block. However correct pinion height is meant to be fine tuned according to contact pattern, so reusing the old height shims as a starting point should be acceptable rather than setting to the specified height.

    If it's a rover diff you would need to check which bearings you'd need as there's different combinations of imperial and metric.
    1975 S3 Ute with Toyota 13bt, H55f + transfer, Holset he221w turbo.

  8. #8
    Join Date
    Jun 2009
    Location
    australia
    Posts
    836
    Quote Originally Posted by flyboy View Post
    Hi all,
    Iíve got my head around putting my gearbox back together, so whilst waiting for replacement parts, I decided to strip the rear axle.
    All went well, and on inspection of the rear diff, I initially thought everything looked good, however the carrier has sheared where one of the side bearings sits. I never drove this car, but it seems the half shaft was keeping everything somewhat lined up.
    The axle casing has a large dent, where Iím guessing in the past a more substantial diff failure has caused the casing damage.
    I noticed i can get a new carrier, but Iím not sure Iím equipped to fiddle with the diff centre...Iím tempted to search for an entire rear axle with diff.
    Iím in NSW Southern Highlands. Can anyone advise if Landrover Heaven sells used parts? or if someone has swapped over a carrier on their diff, could you advise on the difficulty.

    Thanks guys!
    Marcus
    hi mrcas i have a complete rear diff brake drum to brake drum from a 86 inch jim
    Russell Rovers
    Series I Parts Specialists
    russellrovers AT gmail.com
    Phone 0428732001

  9. #9
    Join Date
    Jun 2010
    Location
    Exeter, Southern Highlands NSW
    Posts
    57
    Thanks Jim,
    Iíve got it now in bits. Will clean and inspect and work out which way to go.
    Where are you located?
    Marcus

    2014 Defender SWB
    1959 Series II Ute

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