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Discussion Starter #1
Hello,

Does anyone have any experience in dismantling a rear diff on a 1997 model? I took it out and now I have it on my workbench.



I need to get the crown wheel and the pinion out of the assembly, so I can replace them both.

The pinion has two broken teeth and damaged the crown wheel.





Has anyone tried to do this on their own or is this a specialist job only?

I have a well-equiped workshop and the Range Rover Workshop Manual. In the Manual I only found how to take the rear diff out, but there is nothing on how to dissasemble the diff assembly and nothing about the torque values for re-assembly.

Is there a resource anywhere on the net or does anyone know how to do this? I did a search on these forums, but I didn't find anything relevant to my problem. I did find a topic about a front diff bearing change and the author mentioned that he had to have the whole axle washed and cleaned of debris. I suppose I will have to do that as well? Are there any recommendations on what fluids to use to rinse the axle? Any help is welcome and appreciated.

Regards,
Vito
 

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It would be in your best interest to take it to a good shop and let someone who is experienced repair it. Then you can put it back in yourself.
I say this with 30+ years as a drivtrain specialist. Pinion depth calculation , bearing preload, and clearance values are very important.
It also takes a few specialty tools and a bearing press.
It should run you 3-5 hrs labor for a bench repair including teardown and inspection of the carrier internals.
One last comment, please add your location to your profile if you expect to find local help.
 

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Discussion Starter #3
So the best solution would be to buy a reconditioned assembly and flush the axle in case any debris made it there?

Do you think about 350 GBP is a fair price for a reconditioned assembly which I can buy in the UK?

Do you think I can just get the crown wheel and pinion and then take it all to a specialist so he can repair it or do I need to take it all to a Land Rover specialist? I ask because for about 110 GBP I can get just the crown wheel and the pinion.


Sadly here in Slovenia the Land Rover dealership would just try to sell me a complete new axle, which I think I don't need.
 

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Early diffs were i think a 2 or 3 pin carrier, later updated around the time of Bosch and 4 wheel abs, i would not bother with the older weaker design
 

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I think kerosene or varsol [paint thinner would be OK. Then blow out with air. I guess the safest would be to pull the outer hubs and then clean the carcass. Possibly a garden sprayer would be usefull. Interesting piece of machinery. I needed ring and pinion for my former 1936 series 40 Buick coupe. One of the differential carrier bearings let go and your unit looks almost exactly the same. I got a used rear end, new bearings [single race ball bearings] and had a shop changeover the gears and put in the new bearings. They used colored lead powder to check for the proper mesh pattern of the teeth. I'm not sure about preload on the bearings or the gear backlash but specs must be available. Having said that, if a shop charges 3-5 hours as estimated by g then the price difference is not that excessive. I once had a '73 Saab and moved the ring & pinion .003 thousands closer together in an effort to reduce gear backlash which seemed excessive. 30,000 miles later the pinion gear sheared off its shaft. Were you doing something that loaded the diff unit which caused the failure. You might also pm Selby on this site since he went thru a diff change also. I appreciate you wanting to keep your own parts in there, rather then someone else's part that has been rebuilt so good luck with your quest and let us know of your progress.
 

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RangeOver said:
Do you think about 350 GBP is a fair price for a reconditioned assembly which I can buy in the UK?
I'd say that is pretty good value if it is from a reliable source. Is that Ashcroft Transmissions?
 

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Discussion Starter #7
The Crown wheel and pinion I found on Ebay and I found the reconditioned one at Rimmerbros. Thank you for the Ashcroft info.

I am still looking for a diff specialist, but I think the best solution for me will have to be a reconditioned one as for now I did not find a good specialist for differentials here.

Looking at the Ashcroft page, I'm leaning strongly towards getting one of their diffs. Thanks again for the tip.
 

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Discussion Starter #8
Hi guys,
as most of you might be doing as well, I am still looking how to repair it by myself.

isn't inserting an ARB locker almost the same job? You have to remove the crown wheel, insert it on the locker, put it all together and adjust everything.
On Devon 4x4 I have found a pictorial guide to fitting an ARB RD56 air locker in a Land Rover differential. - Articles courtesy of Land Rover Monthly magazine. - in pdf.
In there almost all of what I need to do that job by mayself is explained, isn't it? Basically, I'm just missing instructions on how to change the pinion?

I searched the forum and found the thread "Differential Pinion Seal and Flange Replacement - DIY PICs" with nice pictures on how to replace seal. There one can see what the pinion asembly looks like inside from that side.

I have a 50 ton bearing press and a lathe and a universal milling machine, etc. For me it is no problem to make any kind of special tools if needed.

Should I find any instructions on the pinion I will then try and dismantle the assembly and put it back together with the new parts and make sure I document the whole thing for the benefit of all.

Any help is appreciated on how to remove the pinion and not break something. Is there anything else that needs to be adjusted on the pinion side, besides the bearings?
 

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Discussion Starter #9
Hello again.

After taking the diff to an expert, I had to admit defeat. It turns out that all his work, materials and such would cost me quite a bit and I might as well just get the recon. diff.

Thanks for all the advice you guys provided, I might have done something silly if I hadn't come here.

I'll keep you guys posted should I run into any new and unexpected trouble.
 
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