tireetim

Member
I have just had my defender 90 (2.4 puma) serviced and asked them to check out a whining noise from the back and they told me it's the rear diff. Said there was shards of metal in the oil when then changed it. I was wondering how easy it would be for an amateur to swap this for a reconditioned one? I have done some basic mechanic stuff on other cars but following a haynes manual so it was fairly straight forward. I can't find anything similar for the later defenders (Haynes only seem to go up to 2006). I have got the workshop manual with the technical stuff (oil spec / quantities etc.) but it's not a step by step guide. I am very keen to learn and would rather do it myself but don't want to bite off more then I can chew or have the car off the road for too long.
Found loads of great info on here but can't find a step by step guide so just wondering if you think I should give it a go or if it would be too much.
Thanks !
 
Not my area, but I am 90% sure that the rear diff is the same as it always has been in a 90, so the older haynes should still apply.

Also, try to find a land rover workshop manual, they are better than haynes and have pictures you can see!
 
OK thanks for that. Just been to Halfords and got their 200 piece socket set (down from £300 to £125 at the moment) and some new axle stands. A new mechanic in the making !
 
A couple of questions already - seen a video where the chap uses some sort of sealant to stick the gasket on, what is that stuff called?
Also, can I take the half shafts out without draining the diff oil or will it all just come out?
Thanks.
 
A couple of questions already - seen a video where the chap uses some sort of sealant to stick the gasket on, what is that stuff called?
Also, can I take the half shafts out without draining the diff oil or will it all just come out?
Thanks.

Depends, if using a gasket most use something like a smear of blue hylomar. Or do away with the gasket and use RTV.

Yes halfshafts will come out without much oil unless your on a side slope but you'll need to drain anyway to pull the diff out.
 
OK thanks for that. Just been to Halfords and got their 200 piece socket set (down from £300 to £125 at the moment) and some new axle stands. A new mechanic in the making !

good on you :)

get a trolley jack that goes up high as well.

watch a vid or two on applying rtv, you don't stick loads on else when you tighten up, it'll just all squeeze out.

you will also need lots of ep90 for other bits, so if you can buy a large amount, hopefully it will cost less.
 
thanks Blue / trax.

OK today I took the half shafts off to check them. The splines don't look very worn. There is a very small amount of play between the half shafts and the drive flange but there seems to be quite a bit of play at the diff end. Not sure how much to expect so took a quick video to see if it's normal or not?

IMG 1183 - YouTube

Maybe it's normal for a landy but I'm also getting quite a bit of what I think is called backlash (thumping when you lift the clutch or a sort of loose rattling sound if you push the clutch whilst going at a steady speed). Feels like play in the transmission so I am trying to find the cause of that at the same time.
 
There re a lot of things that cause clunking when taking up or releasing drive. Maybe part of your problem is the diff mechanism itself, but other possibilities are loose universal joints on the propshaft(s), as well as slack in the splines between the half shafts and drive flanges.

I see from various discussions on the internet that the diff in the Puma is more akin to the one on the P38 Range Rover rather than the earlier Defenders.
DEFENDER2.NET - View topic - ATB (torsen) front and rear install near the bottom of the first page. But it's a very similar looking device.
 
Good sets those Halfords pro ones. I've got the small set that's £60 at the moment. It's lightweight and easy to handle so it lives in the back of the defender at all times! It's done most jobs on the defender and I've just added the odd extra socket or spanner as required.

Make sure your axle stands are up to the weight. I got truck ones for mine :)
 
OK thanks. I will systematically go through everything and check to find out where the play is and it's a good way to learn too whilst I don't need the car on the road for a bit.
I agree Sp00k - very happy with the quality of the Halfords socket set, feels well made and with the lifetime guarantee is a great buy. I took the axle stands back however as they don't go very high and were quite expensive for what they are. Ordered some taller 6 tonne ones off ebay and a high lift trolley jack :)
 

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