Metal Bits on Rear Differential Magnet

[Ansley Rover]

I was just changing the diff oil on my 2003 Disco 2. When I pulled the rear drain plug, the oil had a metallic sheen to it and a lot of fine particles on the magnet - way more than the front or what I’m used to seeing. When I felt through the particles I found these bits in the picture. How worried should I be? I’ve bought the vehicle at 82,000 miles and have just under 86,000 on it now.

 

[Grnrvrs]

Clean up the bits from the 2nd pic and get some clear pics. Big metal bits are concerning.

 

[Caligula]

shaved metal on magnet is totally normal specially if service interval has been overlooked, the bits tho are of concern. could be a failed bearing or a piece of a gear tooth, it would be wise to remove differential and perform an in-depth inspection.

 

[Angus]

The big pieces look like a bearing roller and part of the race. I would pill the 3rd member and look before more damage is done. Inspect the ring and pinion closely for damage.

 

[Ansley Rover]

Thank y'all. Now just have to find the time to pull it out and let the Disco sit in the garage immobile for a week while I work on it after the kids have gone to bed!

 

[1of40]

Pick up a used one at a junk yard.

 

[rocky]

I’d start looking for another Diff. Hopefully you can track down a used one.

 

[jymmiejamz]

I’d consider that normal for a D2. They changed the machining process of the gears in the diff for the d2 which is why they came with a magnetic drain plug and also got the diff fluid changed at the first service if I remember correctly.

 

[Ansley Rover]

I’d start looking for another Diff. Hopefully you can track down a used one.

So this is actually the impetus of my initial question, how worried should I be?. At some point, it’s going to fail. Are we talking definitely going to grenade within 5k and I’ll lose all forward momentum and ability to move or more likely begin feeling rough transitions and a slow deterioration over 10k? Where am I on the spectrum?

I’m going to pull the 3rd member and inspect and we have other vehicles while I do it. But I don’t want to upend my whole family’s next few weekends so I can spend time doing something that I otherwise would do as time allows.

 

[Ansley Rover]

The big pieces look like a bearing roller and part of the race. I would pill the 3rd member and look before more damage is done. Inspect the ring and pinion closely for damage.

Not doing further damage if it’s just a bearing is why I want to immediately pull it into the garage and start pulling things apart. But if the gear teeth are on their way out and I’ll neeed a whole new diff, I don’t want to waste my time inspecting.

 

[Angus]

I don't know how rusty your truck it, but I rebuilt both diffs with new bearings and Ashcroft LSDs in a (long) day. I personally would not drive it until I know what was going on due to the potential of locking up the diff with debris. Pull the 3rd member and look at it. If bad, simply install the 3rd member for another like diff or rebuild yours.

 

[Ansley Rover]

Might as well get after it. Thanks.

 

[evilfij]

So the pin looks like the pin that holds the bearing nut in place (who knows when it fell out or why — is the bearing nut backing off now etc.)

The shavings themselves seem like a lot, but I don’t have a DII with magnetic plugs to know for sure.

Me, I would yolo it unless the diff was loud, but don’t do what I do. Especially because on an 03, it does not have a diff lock so you can’t do the pull the driveshaft, lock the center diff, and get home in front wheel drive.

 

[expanse]

A - if you have a high tolerance for a critical failure, ie stranded on the side of the road, towing bills are of no concern, full send it till boom or you get to fixing it.
or
B - if not, get on to fixing it.

as with all things truck related, it could go 2 more feet or 2 more years till it goes boom. i'd say crack open a few knuckles and get on fixing it now vs. later

 

[rocky]

The need to replace it will be obvious once it’s pulled.

Unless he has retrofitted a CDL, if the rear differential grenades, he’ll be stuck on the side of the road.

 

[Caligula]

on an 87 rangie, I had similar failure some time around 2000. the center pin to spider gears spun and locked it self, then broke and parts fell in ring and pinion as I drove.
this caused a spider gear to fall and wedge or get caught by ring gear at which time a broken piece of spider gear shot out of the back of the housing leaving a hole the size of a .38 caliber bullet. when this happened I was traveling off road at about 35 mph. the back end locked briefly and the car drifted a bit.
I did not loose forward motion as T case was locked. I kept on going and a second piece wedged again, this time locking the whole drivetrain, grenading a cv joint and breaking a front axle.

this failure made me upgrade to 24 splines and arbs. very expensive failure and oversight.
moral of story. investigate and repair or replace ASAP. do not drive it.

 

[Ansley Rover]

Thanks guys. Y’all have convinced me to park it and start pulling it apart.

When I looked at their website, I was surprised that the reconditioned diffs from Ashcroft are as reasonable as they are given the heft of the metal and the precision involved.

 

[rocky]

Thanks guys. Y’all have convinced me to park it and start pulling it apart.

When I looked at their website, I was surprised that the reconditioned diffs from Ashcroft are as reasonable as they are given the heft of the metal and the precision involved.

If you can't find a used one here, just close your eyes on the cost of freight from England and do it.

 

[LRNAD90]

Thanks guys. Y’all have convinced me to park it and start pulling it apart.

When I looked at their website, I was surprised that the reconditioned diffs from Ashcroft are as reasonable as they are given the heft of the metal and the precision involved.

Winchester Gears in UK also has a good reputation, and are generally a little cheaper than Ashcroft..

 

[Ansley Rover]

If you can't find a used one here, just close your eyes on the cost of freight from England and do it.

Ah, they got me with "Shipping option: overseas packaging charge" -- not shipping charge!