Guide on how to replace rear diff bearings and seals
Hi Guys
I bought my LR3 second hand, and of course the previous owner did not change diff fluids in timely matter, causing the bearings overheat. I have changed the fluid, just to see if it will help a bit with a humming noise however I don't quite see any significant improvements. Since I can not afford a new or rebuild unit I have decided to have it rebuilt my self. Besides I could not pass on a learning opportunity here. I bought on Ebay a"LAND ROVER LR3 LR4 RANGE ROVER SPORT REAR DIFFERENTIAL BEARING KIT NON-LOCKER".
Did anybody has done similar job by them self ? Do you guys have any input on what I plan on getting my self into ?
Great thanks
FYI I will try to document the whole process and share with you
23rd Jul 2015 7:07 pm
Nodge68
Member Since: 05 Sep 2014
Location: Newquay
Posts: 1014
There's a good diff rebuild guide here http://www.pirate4x4.com/articles/tech/billavista/Gear_Setup
However I wouldn't take the pinion out unless the bearings feel rough when turned. The rest should be reasonably easy.Freelander SE 2005 Auto.
D3 TDV6. Gone.
That is indeed excellent article, thank you very much. I have already read it twice, and each time got more and more out of it. I have also watched bunch of youtube videos on how an open diff works and what are the generic steps to rebuild one. From what I see now, it seems pretty straight forward (a lot of new terminology) and only really crucial and complicated part is installing a correct shims and setting up a backlash.
That brings me to another question. Do you guys know correct settings for a backlash along with on how and where to get the ships with correct thickens ? Are those generic or need to be specific for the diff. In addition do you know correct settings/specs for a preload on a pinion and carrier bearings?
Thank You in advance.
24th Jul 2015 3:56 pm
Nodge68
Member Since: 05 Sep 2014
Location: Newquay
Posts: 1014
I don't believe that there are any published figures for the diffs. However there's nothing to stop you doing some basic measuring before stripping it down. The pinion is likely to be the hardest part to get right which is why I'd suggest leaving it alone unless absolutely necessary.
Do a search for Dana axle preloads for a rough guide. There's a Dana type 44 pdf on the net which shows the tear down procedure and how to measure crown wheel backlash. This measurement can be used for getting the shims correct on reassembly. The clamshell design is different but measuring is the same
I'm also going to need a rebuild on both diffs, as and when time and funds allow.Freelander SE 2005 Auto.
D3 TDV6. Gone.
24th Jul 2015 6:50 pm
Hank
Member Since: 31 Dec 2007
Location: USA
Posts: 13
2005
LR3
non-locking
I've got a rear diff making some racket. I suspect a bearing(s).
I'm up to tackling the job myself, however I've got a few questions I can't find the answer to. Thanks in advance for any help.
I have an exploded view of the diff from the Land Rover training manual. The manual lists specific parts and pieces, and the order they go together, but it does not list part numbers.
In searching I see newly rebuilt diffs for sale ($1300usd), and I also see rebuild kits ($350usd to $450usd). I'm game for a rebuild, but I'm not understanding the rebuild kit. http://www.roverparts.com/Parts/DOK008 is the kit I'm talking about.
My main concern is what the rebuild kit contains. I see from the photos six bearings and three seals.
What I do not see is the o-ring gasket that goes between the two halves of the diff housing, nor do I see a new crush-sleeve or collapsible spacer. I'm also curious if there are any other parts not included in this kit that should be on-hand just in case, I.E. is there a thrust washer or carrier component famous for going bad?
I can deal with not having a new o-ring gasket. Right Stuff is commonly available. But what about the crush-sleeve? It seems to me like this would be included in the kit if the pinion bearing were to be replaced. Do people reuse the removed crush-sleeve?
Any links for photos pertain to the rebuild would be nice as well.
6th Aug 2015 3:16 am
Robbie
Member Since: 05 Feb 2006
Location: ¯\_(ツ)_/¯
Posts: 17932
Member Since: 05 Sep 2014
Location: Newquay
Posts: 1014
Hank wrote:
2005
LR3
non-locking
I've got a rear diff making some racket. I suspect a bearing(s).
I'm up to tackling the job myself, however I've got a few questions I can't find the answer to. Thanks in advance for any help.
I have an exploded view of the diff from the Land Rover training manual. The manual lists specific parts and pieces, and the order they go together, but it does not list part numbers.
In searching I see newly rebuilt diffs for sale ($1300usd), and I also see rebuild kits ($350usd to $450usd). I'm game for a rebuild, but I'm not understanding the rebuild kit. http://www.roverparts.com/Parts/DOK008 is the kit I'm talking about.
My main concern is what the rebuild kit contains. I see from the photos six bearings and three seals.
What I do not see is the o-ring gasket that goes between the two halves of the diff housing, nor do I see a new crush-sleeve or collapsible spacer. I'm also curious if there are any other parts not included in this kit that should be on-hand just in case, I.E. is there a thrust washer or carrier component famous for going bad?
I can deal with not having a new o-ring gasket. Right Stuff is commonly available. But what about the crush-sleeve? It seems to me like this would be included in the kit if the pinion bearing were to be replaced. Do people reuse the removed crush-sleeve?
Any links for photos pertain to the rebuild would be nice as well.
Here in the UK, rear diff rebuild kits can be had for around 150 GBP. It mightbe worth getting one shipped to the US to save you a few bucks.
The casing O ring should be available from an LR dealer.
I'd not mess with the pinion or its bearings. This eliminates the need for the crush tube. Freelander SE 2005 Auto.
D3 TDV6. Gone.
6th Aug 2015 9:49 am
Nodge68
Member Since: 05 Sep 2014
Location: Newquay
Posts: 1014
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6th Aug 2015 9:59 am
Hank
Member Since: 31 Dec 2007
Location: USA
Posts: 13
Nodge68 wrote:
Hank wrote:
2005
LR3
non-locking
I've got a rear diff making some racket. I suspect a bearing(s).
I'm up to tackling the job myself, however I've got a few questions I can't find the answer to. Thanks in advance for any help.
I have an exploded view of the diff from the Land Rover training manual. The manual lists specific parts and pieces, and the order they go together, but it does not list part numbers.
In searching I see newly rebuilt diffs for sale ($1300usd), and I also see rebuild kits ($350usd to $450usd). I'm game for a rebuild, but I'm not understanding the rebuild kit. http://www.roverparts.com/Parts/DOK008 is the kit I'm talking about.
My main concern is what the rebuild kit contains. I see from the photos six bearings and three seals.
What I do not see is the o-ring gasket that goes between the two halves of the diff housing, nor do I see a new crush-sleeve or collapsible spacer. I'm also curious if there are any other parts not included in this kit that should be on-hand just in case, I.E. is there a thrust washer or carrier component famous for going bad?
I can deal with not having a new o-ring gasket. Right Stuff is commonly available. But what about the crush-sleeve? It seems to me like this would be included in the kit if the pinion bearing were to be replaced. Do people reuse the removed crush-sleeve?
Any links for photos pertain to the rebuild would be nice as well.
Here in the UK, rear diff rebuild kits can be had for around 150 GBP. It mightbe worth getting one shipped to the US to save you a few bucks.
The casing O ring should be available from an LR dealer.
I'd not mess with the pinion or its bearings. This eliminates the need for the crush tube.
Until the diff is removed, how do we know it's not the pinion bearing making the noise?
6th Aug 2015 2:47 pm
Nodge68
Member Since: 05 Sep 2014
Location: Newquay
Posts: 1014
@Hank.
You will need to strip the diff to check the pinion bearings. From the diffs I've rebuilt over the years, the pinion bearings take the least hammering. Sometimes a badly worn or out of balance prop shaft can damage pinion bearings but often they are quite serviceable. Have you drained the oil to check for water contamination?Freelander SE 2005 Auto.
D3 TDV6. Gone.
6th Aug 2015 10:54 pm
Hank
Member Since: 31 Dec 2007
Location: USA
Posts: 13
130,000 miles on the clock currently. The diff fluid has been changed at least twice since owning the truck, maybe three times. The truck was purchased used at 30,000 miles.
The last fluid change was at ~120,000 miles. Everything looked normal. I have not looked at the fluid since the noises have started and probably will not until the diff is removed for repair.
I've ordered the rebuild kit. The crush sleeve was not available from the same place I got the rebuild kit from so I still need to order that. Since no one seems to have documented a rebuild of the rear diff in these trucks, I'll try to take some photos of the process and post up once complete.
7th Aug 2015 3:02 pm
Sly666
Member Since: 15 Dec 2014
Location: East Sussex
Posts: 459
Is there a guide on removing the rear diff from the car?
I need to change mine but have no idea!
Can it be done on axle stands?
I was toying with rebuilding, fitting a second hand one, or fitting a re-conditioned one, then i found Island 4x4 are doing them new for £580 +VAT
Seems good to me. I can afford this if i fit it myself.
8th Aug 2015 10:35 pm
Allan_T
Member Since: 10 Sep 2012
Location: Northampton
Posts: 1034
@Sly666
Speak to Gary at City Gearboxes Coventry, I've just purchased a reconditioned exchange front differential for £474 inc VAT
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8th Aug 2015 10:50 pm
Alphamale
Member Since: 28 May 2014
Location: Belfast
Posts: 496
I've read a lot of the available literature found on the NET and viewed a few of the youtube videos, they all make a diff rebuild very practicable and I know I could do one. However, there is one glaring difference between all these and the D3 diff,.......they are all accessible via the rear diff pan, but the D3 diff has no pan and measuring backlash etc is not as simple task.
Quite apart from these difficulties access to the crush sleeve seems impossible and if you do get one the specifications for the diff are not readily available. So before you jump in and strip your diff make sure you can get as much info as you can.
If any one has knowledge of where to get the crush sleeve and other specs I would be grateful for it.
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