Distorted Defender diff carrier.

[lotus_esprit_s1]

Rebuilding the front axle of my Puma Defender. It is running a stronger differential setup due to the original factory diff letting go on the first owner. I am doing some work on the front axle so pulled the diff to check backlash and found that one side would not adjust up. Stripped the diff centre out and found unusual wear pattern in the bearing on the side which wouldn’t adjust.

The diff carrier has been modified with a known “pegging” modification to strengthen it, however it appears the welding involved with this mod has distorted the carrier fractionally, causing the bearing race to distort when clamped up - when the race is dropped in the carrier, it sits approx 1mm off, however will slot down easily, but is distorting when pushed in place. I am pretty much resigned to buying a new modified casing at £300, however as I have nothing to loose wondered if this case could be rectified. (Due to the modification, the locking centre has been modified to suit and requires a modified casing)

Any ideas? I did wonder about strategically welding the case to try and pull the sides of the diff carrier outwards.

Hopefully the photos help describe the problem - green arrows show where the bearing is being distorted

 

[8ob]

Not familiar with that particular diff, is the housing round when the bolts are torqued up? The landy salisbury diff needed a tool for spreading the carrier to release the diff for much the same reason but it was ok when all the bolts were torqued up. Just thoughts.

Bob

 

[sako243]

Only the Salisbury required stretching. It's basically a rover diff @8ob albeit with a shorter front casing and diff housing.

 

[Tinbasherdan]

Only the Salisbury required stretching. It's basically a rover diff @8ob albeit with a shorter front casing and diff housing.

The puma front is a long nose isn’t it? Only the rears were short nose rover hd units? I’ve got a short nose carrier in my long nose front, it took some machining but it’s in there giving me a hd 4 pin up front.
My guess would be the housing is scrap, I don’t think you’d get it back without line boring. Who did the pegging?

 

[sako243]

short nose rover hd units

That doesn't guarantee anything I think. The 4.6 P38s got a 4 pin (well technically a 2 pin but four gears) and I think all the 110s got the 4 pin diff in the rear. In the long nose casings it was a complete gamble I think whether you got the "2 pin" or "4 pin".

 

[Tinbasherdan]

That doesn't guarantee anything I think. The 4.6 P38s got a 4 pin (well technically a 2 pin but four gears) and I think all the 110s got the 4 pin diff in the rear. In the long nose casings it was a complete gamble I think whether you got the "2 pin" or "4 pin".

As far as I’m aware the long nose 4 pin was only available as a 10 spline unit in the v8 90 rears as an optional extra.
The op is talking about his front diff I believe which should just be a standard 24 spline long nose diff

 

[sako243]

I thought some of the Puma fronts were supposed to be 4 pin but then the axle tubes kept bending on those so

Still reckon the 300Tdis were probably the pinnacle of quality for LR.

 

[tom2207]

I thought some of the Puma fronts were supposed to be 4 pin but then the axle tubes kept bending on those so

Still reckon the 300Tdis were probably the pinnacle of quality for LR.

200 tdi and 300 axles make for something thats indestructible , still wouldnt pull a soldier off yer sister ,, but they dont explode. Cant see a handy way of pulling that carrier back though.

 

[Tinbasherdan]

200 tdi and 300 axles make for something thats indestructible , still wouldnt pull a soldier off yer sister ,, but they dont explode. Cant see a handy way of pulling that carrier back though.

Aside from the weak diff, weak half shafts, and a tendency to bend tubes if properly hammered? Besides going imperial there’s not a whole lot of difference between a series 3 10 spline and a 200tdi 10 spline. 300 went to 24 spline which is an improvement but not what I’d call indestructible

 

[Tinbasherdan]

I thought some of the Puma fronts were supposed to be 4 pin but then the axle tubes kept bending on those so

Still reckon the 300Tdis were probably the pinnacle of quality for LR.

If you want strong, run a front salisbury

 

[lotus_esprit_s1]

I thought some of the Puma fronts were supposed to be 4 pin but then the axle tubes kept bending on those so

Still reckon the 300Tdis were probably the pinnacle of quality for LR.

Puma 110 fronts were often but not always 4 pin front from 2010ish. This one wasn’t and failed so was replaced by the pegged Ashcroft unit above by the previous owner.
The Puma does have stronger front driveshafts though, and HD one piece rears from 2015.

I think I’m going to have to get a new case.

 

[sako243]

I think I’m going to have to get a new case.

Unsurprisingly @8ob has a pile...

 

[Tinbasherdan]

Puma 110 fronts were often but not always 4 pin front from 2010ish. This one wasn’t and failed so was replaced by the pegged Ashcroft unit above by the previous owner.
The Puma does have stronger front driveshafts though, and HD one piece rears from 2015.

I think I’m going to have to get a new case.

Casings should be easy to get hold of. What are you doing with it that requires a pegged diff?

 

[sako243]

I don't think Ashcrofts particularly enjoy doing diffs anymore. Referring them down to Nige at Xcess 4x4. I've heard a few bad stories about Ashcrofts work but nothing about Nige. The two pegged lockers he built me 6ish years ago have been absolutely perfect. In fact I've got the very first pegged Ashlocker in a short nose in the rear of my 110. Should probably change the oil...

 

[8ob]

Unsurprisingly @8ob has a pile...

Puma 110 fronts were often but not always 4 pin front from 2010ish. This one wasn’t and failed so was replaced by the pegged Ashcroft unit above by the previous owner.
The Puma does have stronger front driveshafts though, and HD one piece rears from 2015.

I think I’m going to have to get a new case.

If any of the ones I have here are what you are looking for you are more than welcome to one, I was about to cut up a pile of them because Eds mate wanted them to modify.

Bob

 

[lotus_esprit_s1]

Casings should be easy to get hold of. What are you doing with it that requires a pegged diff?

Nothing, however as the previous owner opted to fit a pegged setup the centre has been machined down for the pegging so it has now lost a lot of strength around the crownwheel, so needs to go back in a pegged casing.

As a last resort as I have nothing to loose I may try cutting another top cap in half and bolting it to the casing, heating it up and strategically jacking between the two halves of the top cap.

Thanks for the offers of the casings, I do actually have a few myself, it’s just the hassle as I’m going to have to ship one away to get it pegged and machined

 

[sako243]

I was about to cut up a pile of them because Eds mate wanted them to modify.

You've been about to cut them up for about half a year...

 

[Tinbasherdan]

Nothing, however as the previous owner opted to fit a pegged setup the centre has been machined down for the pegging so it has now lost a lot of strength around the crownwheel, so needs to go back in a pegged casing.

As a last resort as I have nothing to loose I may try cutting another top cap in half and bolting it to the casing, heating it up and strategically jacking between the two halves of the top cap.

Thanks for the offers of the casings, I do actually have a few myself, it’s just the hassle as I’m going to have to ship one away to get it pegged and machined

I tho I I’d just be putting a complete diff in and saving the hassle, myself

 

[lotus_esprit_s1]

I tho I I’d just be putting a complete diff in and saving the hassle, myself

But then I’d be doing it again in six months when the TDCi has chewed up the standard centre!

 

[Tinbasherdan]

But then I’d be doing it again in six months when the TDCi has chewed up the standard centre!

Don’t drive like a deranged ape and you’ll be fine only time I’ve blown diffs is driving like a loon in a trial