The pinion appears to have broken off whole - is there any lateral play in it?

Presumably for the case to crack like that the teeth on the crown and pinion gears have jammed - ie not mated correctly.
 
I would 2nd checking the oil in the IRD as, unless the diff just lost its oil, presumably the transmission has been under stress previously. If the oil that comes out is grey/metalicy its shagged, check lateral play on pinion and also where drivers side CV plugs in - although if its been running smoothly the CV mount should be OK.

Interestingly, you can get brand new OEM IRDs for only a little more than the cost of a recon IRD...

https://www.lrdirect.com/TAG000230-Transfer-Box-Ird-Freelander-Ex/
https://www.lrdirect.com/TAG000230-Transfer-Box-Ird-Freelander-Ex/
Still a lot of cash though!

Diffs are usually a safer bet 2nd hand (compared to an IRD)
 
My guess is ya pinion gear was loose or not set right. The fact you had ya prop off and hit the pot hole must have jolted the gears into non mesh mode and Boom! May not have happened with ya prop on as it would have helped it round and kept pinion in place...

looks bone dry too was there any evidence of oil in there?

Also great pics keep them coming...Love a bit of diff porn.
 
Well that's the 2nd hand diff in just need to fit top bush mount. To cold,not much fun up on axle stands with snow on the ground . Touch wood the diff is a good one. The oil remaining in it was clean. The teeth look a bit worse as I drove it 2 miles to get home with them rubbing on the sub frame. Will check front tommorow.
 
Just a thought. Wife says handbrake was stuck on in the morning. She had to go back and forward a few times till they released with a thud. It had happened the last three days.
 
Spitfirejim said:
Just a thought. Wife says handbrake was stuck on in the morning. She had to go back and forward a few times till they released with a thud. It had happened the last three days.
Click to expand...
Do you live near a ford?

When my brakes have got wet from launching my boat, if the hand brake is left on overnight the rear brakes will be siezed up in the morning.

In your case though, probably frozen solid - but would need moisture in there.

Dunno if it would damage the diff but, especially in 2WD, if only 1 side was locked or they release at different times, then it ain't going to do it any good I suppose.
 
The hand brake has nothing to do with the diff going bang. The HB acts on the drum, which is bolted to the wheels by 5 M12 wheel studs. You could yank on the HB lever at 60Mph and do no damage to the diff. This issue isn't related to anything other than the VCU/ tyres.
 
Nodge68 said:
The hand brake has nothing to do with the diff going bang. The HB acts on the drum, which is bolted to the wheels by 5 M12 wheel studs. You could yank on the HB lever at 60Mph and do no damage to the diff. This issue isn't related to anything other than the VCU/ tyres.
Click to expand...
That wouldn't be a very good idea though, in 4WD, because the fronts would still be turning and would put a lot of stress in the transmission, including the rear diff.
 
When I was in 2WD total prop removed after jet washing the car, I reversed off the drive..all ok. Then set off, one of me back wheels jammed on. had to reverse/forward a few time to free it up..put it down to the brake shoes locking up with water somehow...read it can happen with drum brakes...hydro locking or somert...
 
GrumpyGel said:
That wouldn't be a very good idea though, in 4WD, because the fronts would still be turning and would put a lot of stress in the transmission, including the rear diff.
Click to expand...
Maybe that's why the early Freelander's suffered IRD failure, as ABS was an option on some models.
Pulling the HB up while moving, would simply apply a degree of braking to the front, via the VCU.
 
GrumpyGel said:
Could be the snow, @Snaggapuss in Sweden had his front brakes sieze recently in fairly similar conditions - although I don't suppose it was -25 where you are.
Click to expand...

as GrumpyGel says had brakes hang on for a bit, apparently driving in the deep snow and then parking up with letting brakes dry off can give rise to water/melted snow (yes I know its water but....)freezing between pads and disks. lesson learned, let brakes dry off after playing in deep snow.
 
Finished fitting 2nd hand diff and all seems good . No noise or leaks.. Snow back on so never got to change ird oil so just left prop off. Cleaned brake drums where brake dust and water had mixed into a paste. Thanks for all advice.
 
Spitfirejim said:
Finished fitting 2nd hand diff and all seems good . No noise or leaks.. Snow back on so never got to change ird oil so just left prop off. Cleaned brake drums where brake dust and water had mixed into a paste. Thanks for all advice.
Click to expand...
Are you sure its brake dust and water, not brake dust and brake fluid leaking from a cylinder?

I've just renewed my rear brakes because 1 of the cylinders was weeping fluid and it was quite pastey inside.
 
I thought it may be fluid so checked behind rubber boot and looked dry. I will keep a eye on it. Have to read up on how to do a vcu test. I was told if you reverse and no tightness and noise all ok which it was apart from noise support bearings.
 
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