Axle and diff help.

[Disco_Stu]

I recently had an axle failiure. I aquired a second hand axle. There are a few differences. Can those of you out there with experience of these components tell me if i'm heading in the right direction please?

I'm told the axle is off a G reg 200Tdi, mine is a 1994 300tdi.

1. New axle has a 4 bolt fitting for a UJ rather than a 3 bolt rubber coupling - I'm gonna just swap the prop for the 200 one - does this fit/work?

2. I decided to swap the discs, hubs etc from my old axle to the new one. I find the halfshfts are 10 spline where mine were 24. I also find the stub axles are longer on the new axle plus the flanges on the old hubs are deeper. Hence its not a straight swap. I can unbolt the discs from the hubs and see what the bearings in the replacement hubs are like in use - is this advisable?

3. Are there any other differences that you think I need to be aware of?

Thanks for any help you can give, I've tried to be clear but if you need any further info please ask.

Thanks, Stu.

[Henry Webster]

You should be able to fit the 'new' axle with the 'new' propshaft without problems, but mixing and matching components is more difficult between the 10 spline and 24 spline axles.

What is it that failed in your last axle?

H

[Disco_Stu]

See here

http://forums.mud-club.com/viewtopic.php?t=44497

[ChrisW]

You can either use just the axle tube from the new one you have bought and swap *everything* (diff, half shafts, stub axles etc etc) onto it, or fit the new axle complete without changing anything and end up running a 24 spline front and 10 spline rear.
With regards to the prop you can use the 4 bolt flange on the diff to be able to fit a 200 rear prop with a normal UJ at each end rather than the rubber donut at the diff end - you can even take the flange off the 10 spline diff and fit it to the 24 spline diff if you want to.

You haven't got ABS on your Disco have you?

[Disco_Stu]

Thanks for the advice.

I've been back to the bloke with the axles and got the prop as well, so that prob is solved. 10 spline rear and 24 front should be ok, am I right in thinking the 10 is tougher?
If so, the rear is the best place for it. Incidentally, the 10 spline half shafts are thicker throughout, no swelling points for bearings etc.

I haven't got ABS as you say. However, and this is a good one, the bloody caliper bolts from the 300 don't fit the 200. Despite the calipers being the same, the threaded holes in the axles aren't. So its a call to LR in the morning for 4 of those!

I'm hoping to back up and running by Saturday, and totally expert in Disco rear drive trains!

Stu.

[ChrisW]

The 24 spline are stronger - more surface area. If it were me I would be inclined to just use the axle tube and rebuild it back up with all the 24 spline components.

[Thrasher]

They went to 24 for a reason - tougher - as proved by the camel vehicles.

Piglet has no rubber donut - *but* has 24 spline diffs (tru-tracs).

I too would simply rebuild my axle into the new tube ...

[Disco_Stu]

Thats food for thought. I think due to the fact that I've spent a lot of time on this axle now and have re greased, cleaned, polished and rebuilt everything bar the calipers I'll stick with the 10 spline.

I run BFG AT's, so my chances of busting a diff or a shaft are less than some of the simex bad boys. That said, I'll still be able to off road in the happy knowledge that if I do break something, I have a replacement sat in the garage which I can swap out with taking the bloody thing off the car in future :)

Stu.