Patrol Rear Diff Problems

solarman216 · 10-01-2020, 20:25

Hi all, well this has been going on for several months, but till now have not been able to locate the problem, I will start at when I first noticed a problem, sometime late Oct 19 I was driving at around 40 mph on a straight road when I became aware that I was drifting to the right, like wind hitting me through gaps in the trees, only did it once on that trip so thought nothing of it, but over the next months it did it a few more times, then on the way to Slindon in Dec pulling away from lights I had a hard pull to the right accompanied by loud noise like tyre hitting body aggressively, need less to say pulled over and had a look round but nothing seen, last Wednesday it did it again, so on getting home jacked up and checked all the wheels etc, nothing, then on Wednesday this week coming out of Jewsons yard the OSR wheel locked up momentarily, so this morning lifted the OSR wheel and spun it by hand, sweet as a nut,started the engine and ran it in first gear no problem, scratching my head now, so selected 4th and ran it at about 50 mph, then I heard it, horrible graunching noise from the rear diff, that is it car off the road, stole the Mrs T2 (arnt they small) did some running round and by 2pm all done so started on the Troll, got the diff out by 4pm but had a call so did no more, but initial examination show's nothing other than a bit of swarf in the bottom and am convinced this is turnings from manufacture, cannot relate these bits to anything in the diff, so tomorrow will be the big day as have to strip the entire diff to find out what the problem is, and will take pics through the whole procedure, catch you all tomorrow, Rick

solarman216 · 10-01-2020, 21:27

Having given it some thought, I suspect nothing more than a "picked up thrust washer on the OS planet gear, time will tell, Rick

Banshee · 11-01-2020, 00:25

Does that mean we're still getting the strip down Rick?

solarman216 · 11-01-2020, 11:45

Yes got to strip it down completely to find out, starting shortly, Rick

solarman216 · 11-01-2020, 19:36

After dropping the oil these bit were on the magnet, but do not think they are from my diff, more like lathe turnings from manufacture that did not get removed

solarman216 · 11-01-2020, 19:38

Diff lock fork, made it easy to remove carrier

solarman216 · 11-01-2020, 19:39

Diff out

solarman216 · 11-01-2020, 19:42

In the previous pic you can see the heavy dog clutch that is the diff lock, here we are marking so as to get the mating parts back together in their correct places

solarman216 · 11-01-2020, 19:45

Spacer to keep shaft off the oil seal, cannot withdraw them in the workshop

solarman216 · 11-01-2020, 19:46

More marks, you can just see at 12 o'clock

solarman216 · 11-01-2020, 19:48

Dial gauge set to record back lash

solarman216 · 11-01-2020, 19:49

Recorded

solarman216 · 11-01-2020, 19:51

More marks this time light grind to Crown Wheel as it is hard

solarman216 · 11-01-2020, 19:54

After splitting the diff case this is the NS drive gear and thrust washer, all good as gold

solarman216 · 11-01-2020, 19:55

Punch out spider pin locating dowels

10-01-2020, 20:25	#1
solarman216 Off road maniac Join Date: Dec 2009 Location: Bexhill on Sea Vehicle: Y60 Patrol Me, 3 ltr Mrs Posts: 17,321	Patrol Rear Diff Problems Hi all, well this has been going on for several months, but till now have not been able to locate the problem, I will start at when I first noticed a problem, sometime late Oct 19 I was driving at around 40 mph on a straight road when I became aware that I was drifting to the right, like wind hitting me through gaps in the trees, only did it once on that trip so thought nothing of it, but over the next months it did it a few more times, then on the way to Slindon in Dec pulling away from lights I had a hard pull to the right accompanied by loud noise like tyre hitting body aggressively, need less to say pulled over and had a look round but nothing seen, last Wednesday it did it again, so on getting home jacked up and checked all the wheels etc, nothing, then on Wednesday this week coming out of Jewsons yard the OSR wheel locked up momentarily, so this morning lifted the OSR wheel and spun it by hand, sweet as a nut,started the engine and ran it in first gear no problem, scratching my head now, so selected 4th and ran it at about 50 mph, then I heard it, horrible graunching noise from the rear diff, that is it car off the road, stole the Mrs T2 (arnt they small) did some running round and by 2pm all done so started on the Troll, got the diff out by 4pm but had a call so did no more, but initial examination show's nothing other than a bit of swarf in the bottom and am convinced this is turnings from manufacture, cannot relate these bits to anything in the diff, so tomorrow will be the big day as have to strip the entire diff to find out what the problem is, and will take pics through the whole procedure, catch you all tomorrow, Rick __________________ Ex banger racer now off road maniac Lokka on the front with manual hubs Diff lock on rear 3 inch SS straight through exhaust Manly winch bumper with 13000 lb winch 10 spike ground anchor, with multiple straps and blocks Super strong body cills capped with scaffold pole 20% stronger springs all round aggressive off road tyres on wheels so just swap. Aim to get stuck and be completely self sufficient in extraction, love getting muddy, 2ft deep is good but rare.

10-01-2020, 21:27	#2
solarman216 Off road maniac Join Date: Dec 2009 Location: Bexhill on Sea Vehicle: Y60 Patrol Me, 3 ltr Mrs Posts: 17,321	Having given it some thought, I suspect nothing more than a "picked up thrust washer on the OS planet gear, time will tell, Rick __________________ Ex banger racer now off road maniac Lokka on the front with manual hubs Diff lock on rear 3 inch SS straight through exhaust Manly winch bumper with 13000 lb winch 10 spike ground anchor, with multiple straps and blocks Super strong body cills capped with scaffold pole 20% stronger springs all round aggressive off road tyres on wheels so just swap. Aim to get stuck and be completely self sufficient in extraction, love getting muddy, 2ft deep is good but rare.

11-01-2020, 00:25	#3
Banshee Moderator Join Date: Jul 2012 Location: West Midlands Vehicle: 04 2.7 SWB Terrano II Van Posts: 13,525	Does that mean we're still getting the strip down Rick? __________________ Moderator 04' Terrano II SE 2.7 TDi SWB Commercial in Silver - Project Thread Toyo Open Country M/T 33's on 10J Steels, Super Strong Steering Job Navara D22 Snorkel, Front LOKKA, Maunal Hubs, EGR Blank TunitII ECU Chip, 3" Body Lift, 2" Suss Lift, Heat Exchanger Black Interior, 3.0 Borg&Beck Clutch, Eckes Heated Fuel Filter 99' Y61 Patrol GR SE 2.8 TD6 LWB in Blue/Silver - Project Thread Engine Transplant - In Progress!!!

11-01-2020, 11:45	#4
solarman216 Off road maniac Join Date: Dec 2009 Location: Bexhill on Sea Vehicle: Y60 Patrol Me, 3 ltr Mrs Posts: 17,321	Yes got to strip it down completely to find out, starting shortly, Rick __________________ Ex banger racer now off road maniac Lokka on the front with manual hubs Diff lock on rear 3 inch SS straight through exhaust Manly winch bumper with 13000 lb winch 10 spike ground anchor, with multiple straps and blocks Super strong body cills capped with scaffold pole 20% stronger springs all round aggressive off road tyres on wheels so just swap. Aim to get stuck and be completely self sufficient in extraction, love getting muddy, 2ft deep is good but rare.