Dented Diff Cover - Defender Source
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  #1  
Old October 21st, 2012, 12:06 PM
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Chris Baldewin
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Dented Diff Cover

When I stopped to air up after Rover Rendezvous this year I noticed a puddle of oil under my front diff. As I checked it out I noticed that I bashed my front diff cover pretty good. The first problem is the leaking 90wt and the second is that I don't know if anything is rubbing inside the diff. So my goal is to pull the 3rd, inspect, pound out the diff, weld it up and put it all back together.
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  #2  
Old October 21st, 2012, 12:10 PM
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Ouch. I have one I just cut off for Toyota conversion I'd sell for a couple bucks
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  #3  
Old October 21st, 2012, 02:06 PM
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That's too far gone. Better to get a replacement cover then armor plate it.
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A friend of mine runs a land rover / range rover specialty repair shop. Based on his experience, they are capable of stopping anywhere, anytime, at any cost.

I don't know about the brakes, only their unreliability.
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  #4  
Old October 21st, 2012, 03:11 PM
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fyi - here is a link below on a writeup for the sewer cap install.

http://www.pirate4x4.com/forum/land-...r-writeup.html

It would save you the hassle of rewelding the original (paper thin) diff cover back on.
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  #5  
Old October 21st, 2012, 03:41 PM
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Jake thanks but I"m beyond that in this repair already. Jeff tried to sway me on the sewer cap but I'm not sure my welding skills are leak proof yet.
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  #6  
Old October 21st, 2012, 04:30 PM
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Quote:
Originally Posted by Baldewin View Post
Jake thanks but I"m beyond that in this repair already. Jeff tried to sway me on the sewer cap but I'm not sure my welding skills are leak proof yet.
So weld it best you can and seal it with RTV just for insurance
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  #7  
Old October 21st, 2012, 05:47 PM
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Sewer cap
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  #8  
Old October 21st, 2012, 05:55 PM
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Brake Cleaner and JB weld.
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  #9  
Old October 21st, 2012, 06:00 PM
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Quote:
Originally Posted by Baldewin View Post
Jake thanks but I"m beyond that in this repair already. Jeff tried to sway me on the sewer cap but I'm not sure my welding skills are leak proof yet.
No problem with that, Land Rovers always mark the ground.....
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  #10  
Old October 21st, 2012, 06:25 PM
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I'm further along on this than my posts imply. I've pulled the steering knuckles and the third member. What I've learned from this is, if you have leather gaiters it's faster to remove the hose clamp and push the gaiter out of the way. This makes it easier to get the wrench on the 12pt bolts.
Used a double jack, the end of an old shovel and a brass drift to reshape the diff cover. The split was 3/4" long by 1/16" wide and that got sealed up with the mig.
Spent most of today cleaning up every thing for reassemble and painted the diff housings. I also removed the gaiters completely to inspect the swivel balls. They look pretty good, no pitting, just a faint spherical score line at the seal.
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  #11  
Old October 23rd, 2012, 01:37 PM
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Now buy a diff gaurd.
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  #12  
Old October 23rd, 2012, 04:11 PM
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Ron the sad part is I had/have one that I took off for some reason and was too lazy to put back on. I've been razed pretty good by club members
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  #13  
Old October 23rd, 2012, 04:18 PM
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Quote:
Originally Posted by Baldewin View Post
Ron the sad part is I had/have one that I took off for some reason and was too lazy to put back on. I've been razed pretty good by club members
I have a few on the shelf and only one on a truck that I never drive so don't feel too bad.
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  #14  
Old October 23rd, 2012, 08:21 PM
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Originally Posted by Baldewin View Post
Ron the sad part is I had/have one that I took off for some reason and was too lazy to put back on. I've been razed pretty good by club members
I'm one of the said club members. Funny thing is that we were on Heartbreak Ridge the day before bs'ing while waiting for the trucks in front of us to clear an obstacle and Chris said something along the lines of he had the same front diff guard as someone else sitting in the garage at home. Sure enough the next day he ventilated his diff... When he posted up about holing the diff i asked him if his garage was nice and safe from rocks..
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  #15  
Old October 24th, 2012, 01:41 AM
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When I think about it Jake, we were talking about the rear one when we were on Heartbreak Ridge which is also sitting on my garage floor as well.
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  #16  
Old October 24th, 2012, 01:56 AM
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Originally Posted by Baldewin View Post
When I think about it Jake, we were talking about the rear one when we were on Heartbreak Ridge which is also sitting on my garage floor as well.
Touché sir, it was the rear we were talking about.. So is the rear part of tomorrows laundry list too?

I'll be bolting my rear one on tomorrow for this weekend once brown delivers tomorrow. Now only if my just in case shackles would show up by Friday all would be right with the world..
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  #17  
Old October 25th, 2012, 12:04 AM
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OK, the dented diff is done. It looks like a fat ladies ass, but is fully functional. Put the diff guards on front and rear and was able to install the stainless brake lines as part of this project. Jeff the Sierra Nevada picture is for you. After we talked I decided I needed a stool and it was the closet and only thing I had. After that the passenger side popped right it. The truck is ready for Kernville this weekend.
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