Outer Limits 4x4 Board

Went out testing my front locker today getting all crossed up in my county, when i got stuck on my front housing. So i put it in reverse then first to rock the car back and forth off the hump then there is this BANG GRRRRRR coming from my rear diff and no drive to the rear. I got out thinking " its a salisbury (Dana 60), and its open, these dont break i must have done an axle". So i pull out the axles, and they're all still in one piece. "shit i must have done the crownwheel and pinion ive never heard of one of these breaking before on an open diff" so i pull the cover plate off and shine a torch in. nothing. Not even a shaving in the clean oil. "aah bugger it. I'll just get it driving again and look at it later" so i pull the tailshaft out and go to pull the caps off the ends of the axles, and there it was. I spun the axle in the spline of the full floating axle hub. The axle is re-usable but the hub has no spline left at all. Anyone else ever busted one? They weren't flogged excessively.

No they werent maxidrive caps, they dont seem to fit, i need a spacer or somthing.

This is all the coaxing i need to fit that locker to that 95 defender disc rear i have laying around.

Andrew.

one of my mates had a lot of clunking and we narrowed it down to the same thing. It had not let go but it wouldn't have taken much more to do it. I had some extra flanges lying around so we just put them in. (def though)

when i had my rear Maxi-drive locker (sals) fitted to my 1998 d110 tray back mal showed me the stock axles and flanges. they were both twisted/worn. this on a truck that was stock, 95% road driven and at only 90,000km's

serg

Yes, quite common especially in later Defenders. The drive members are made of butter. Plus they are not lubricated due to the addition of a seal on the halfshafts.

Make sure you pull the seal and let oil to the splines and bearing when you switch to a better member and shafts.

As red 90 said, very common in Defenders - don't know why its just them, Discos and Rangies don't seem to chew them out. Wasn't aware that Countys also did that.... But yes, the axle caps often wear out, though its a bit uncommon for them to go to that extent without being noticed - tend to make a fair clunk on takeoff when worn that much. The common fix is to fit Maxidrive axles and axle caps, not sure of availability for countys.... If you have a Defender disc rear end, I'd fit that anyway, then also fit the MD axles and caps

Yeah I've busted one. Have maxi flanges now in the County plus carry a spare

do the strd originals still fit the maxi axles, so if i got one as a spare it would fit

You've now got one up on me Andrew...
Haven't done that (yet)