Bearings are case hardened and polish ground to the exact surface dimensions needed for the application. There are two main bearing failure modes. The first is simply due to wear over time. This wear is normally due to microscopic particles in the oil, wearing the hardened surface off.

The second type of failure is due to overload. In overload situations, the case hardening can literally peel off softer base metal, due the the constant high pressure on the bearing surface. This high pressure will de-laminate the case hardening off the base material. This is the most common failure mode for the IRD bearings.

Does that match the photos above? To me, they look more like damage from metal particles in the photos that appear in the articles shown in the links. Maybe a combination of the two? Maybe just general wear and tear (150,000 is a reasonable innings, I guess?) so that the case hardening is thinned to almost nothing, and then the metal particles in the oil have pierced what's left of it in various places?
 
Maybe a combination of the two?
A combination of mileage, overload and particles in the lubricant is the most likely cause.

The early Discovery 3 suffered a similar issue with the front diff. The bearing which de-lamintes is the one which carries both the diff loadings and the drive shaft support loads. The bearing on the other side of the diff only carries diff loadings, so suffers no real damage, even with particles of metal in the oil.

Near side D3 diff bearing, which supports the diff and drive shaft. This is quite obviously overloaded.

20200104_180146.jpg

Off side, which only supports the diff, as the drive shaft has its own bearing at the other end of the diff casing.
20200104_180132.jpg
 
A combination of mileage, overload and particles in the lubricant is the most likely cause.

The early Discovery 3 suffered a similar issue with the front diff. The bearing which de-lamintes is the one which carries both the diff loadings and the drive shaft support loads. The bearing on the other side of the diff only carries diff loadings, so suffers no real damage, even with particles of metal in the oil.

Near side D3 diff bearing, which supports the diff and drive shaft. This is quite obviously overloaded.

View attachment 197552
Off side, which only supports the diff, as the drive shaft has its own bearing at the other end of the diff casing. View attachment 197553
That'd be similar to the diff bearings in a Freelander's IRD.
 
That'd be similar to the diff bearings in a Freelander's IRD.
Yes the bearing are pretty similar in size and specification, and equally easily overloaded.

The only real difference it the IRD was made by, or at least designed by Steyr, but the D3 diffs are made by Dana.
 
Here's some I prepared earlier! (oil with metallic flecks in it, that is). That's what mine looked out when the bearing started breaking up!
View attachment 197504


Quite pretty really ...in a large-hole-in-the-wallet kind of way!

Here's the magnetic drain plug:

View attachment 197505
Fitted my blanking plate today with new oil in, the drain had a bit of sludge in it and oil seem to be fairly clear just black to say ive changed it only a few months ago. But still have a whining noise the under the car. Any help
 
Fitted my blanking plate today with new oil in, the drain had a bit of sludge in it and oil seem to be fairly clear just black to say ive changed it only a few months ago. But still have a whining noise the under the car. Any help
Is it definitely from the IRD and not the gearbox?

The IRD can make a quiet whining sound (mine does on over-run), but it should be loud.
 
It's definitely worth changing the gearbox oil too, which will improve shift quality, and might cure the noise too.;)
 

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