 | Home > Puma (Tdci) > New axle or repair the original |
 
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| diesel_jim Member Since: 13 Oct 2008 Location: hiding Posts: 6088   
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You could always get a Britpart HD front casing....
https://www.britpart.com/all-parts/da1708 https://www.johncraddockltd.co.uk/land-rov...rt-xd.html Bit spendy though..... better off getting a TUL XD military one as Blackwolf says, Or get yourself a decent straight used axle and weld on this strengthening kit: https://www.tomcatwebshop.co.uk/axle-strengthening-kits-900-p.asp |
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1st Oct 2019 11:36am |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17320 
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The only two failure modes of the late front axle case I have come across are the common (and terrifying) failure of the end flange welds, and the much rarer linear failure of (or adjacent to) the weld along the front of the long-side tube.
The former suggests to me an inadequate welding process with insufficient penetration, or possibly a metalurgical problem resulting in local embrittlement. The latter failure I would suspect is metalurgical exacerbated by the bending of the axle case in use. I would think therefore that reinforcing the end flange welds and fitting a (military-style) gusset or brace under the axle would pretty well eliminate either failure in all but the most exceptional use. If I found that my axle case needed renewing and I couldn't find, or chose not use, a military axle, I think that the actions I would take would be to find the most recent (i.e., least corroded) standard axle case I could get, grind out the end flange welds and reweld properly, then sleeve the welds and gusset the flanges, and then weld a gusset under the full width of the axle tube. I would probably reinforce the radius arm brackets as well. I think this would result in an axle case that was fairly indestructible but not excessively heavy. Another option would be to cut out completely the tubular portions of the axle case and replace them with heavier gauge, possibly CDS, tube, but this would require much more complex and careful jigging. The Britpart axle case is probably fine, but to my eyes it is a hideous fabricated thing which looks as though it was built by an Appalachian banjo player (with no offence intended to any members who live in Appalachia and play the banjo). I wonder also how much oil it requires compared to a normal axle. |
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2nd Oct 2019 7:27am |
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| diesel_jim Member Since: 13 Oct 2008 Location: hiding Posts: 6088
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Yes the last link I posted above is a weld on strengthening kit |
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2nd Oct 2019 7:56am |
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| HardCharger Member Since: 03 Mar 2013 Location: Manila Posts: 731  
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Those were weld ons? OK, will go through the stuff again then. Thanks!
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2nd Oct 2019 8:43am |
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| BogMonster Member Since: 05 Feb 2008 Location: Stanley Posts: 400  
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Fascinating, thanks. I've never heard of any such thing happening here, and a great many Defenders here spend a lot of their time on very rough gravel roads bashing through deep potholes, so take a much harder hammering underneath than most UK vehicles. My own Puma is quite low mileage. I must ask around and see if anybody's come across it on older vehicles. The 'modification' looks like a complete bodge up! The issues people have had here are with non-genuine swivel housings snapping off. Somebody I know once lost both front wheels at the same time (fortunately off road). In fact a family member lost a front wheel off his Prado this morning (more non gen parts) so wheels falling off is a subject I'm quite interested in at the moment! --- 2006 Defender 110 SW 300Tdi • 2011 Ford Ranger XLT crewcab • 2015 Defender 110 Station Wagon Utility TDCi |
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2nd Oct 2019 11:53pm |
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| MikeJ Member Since: 04 May 2014 Location: Dorchester, Dorset Posts: 41 
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I had the second failure over 2 years ago: https://www.defender2.net/forum/post641259.html We chose to weld it up and it's been fine since. That vehicle is a very heavy 130. It has a cherry picker on the back and weighs the full 3.5 tonnes. Mike |
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3rd Oct 2019 12:15pm |
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| Bluericky Member Since: 26 Jun 2014 Location: Cornwall Posts: 647 
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Still looking for a replacement diff but have got the old one out.
Here’s a pic with a couple of lines to show how bent it is . I’ve taken the mid point of the diff housing to the centre of the spring plate. A bit heath Robinson I know but isn’t obvious in a pic !  Click image to enlarge https://www.instagram.com/hustynminepark/ |
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3rd Oct 2019 2:02pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17320
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Mike, it was your failure that I had in mind when I wrote my post. A rare but disturbing failure. |
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3rd Oct 2019 2:13pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17320
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Wow, that is not the way I was expecting it to be bent. |
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3rd Oct 2019 2:14pm |
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| Bluest Member Since: 23 Apr 2016 Location: Lancashire Posts: 4194 
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That’s quite surpring. Wasn’t expecting it to be bent that way. How on earth did that happen? 2007 110 TDCi Station Wagon XS
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3rd Oct 2019 2:22pm |
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| Bluericky Member Since: 26 Jun 2014 Location: Cornwall Posts: 647
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Bluest , I have absolutely no idea how it happened .
There’s not a mark on the axle casing to suggest it’s been bashed . It is however a second hand axle casing and replaced my last axle case that sheered on the weld so I’m assuming the replacement was already bent ! A bit strange that I had no problem putting the half shafts in when I did the swap over though . Having spoken to our local Defender specialist today whilst trying to source a decent casing , he mentioned that he’d seen this a few times before on farmers vehicles and only Pumas. So obviously not a first ! https://www.instagram.com/hustynminepark/ |
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3rd Oct 2019 4:01pm |
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| Bluest Member Since: 23 Apr 2016 Location: Lancashire Posts: 4194
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It's almost like someone has done an aggressive snatch recovery with the rope round the axle. 2007 110 TDCi Station Wagon XS
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3rd Oct 2019 4:08pm |
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| Bluericky Member Since: 26 Jun 2014 Location: Cornwall Posts: 647
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Ive just come across KAM axles , manufactured predominantly for the armoured defender market !
This may be overkill but it’s hugely tempting . Click image to enlarge https://www.totaloffroad.co.uk/equipment/t...ter-axles/ https://www.instagram.com/hustynminepark/ |
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5th Oct 2019 5:53pm |
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| LandRoverAnorak Member Since: 17 Jul 2011 Location: Surrey Posts: 11324
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Looks hugely expensive, too
 Darren
110 USW BUILD THREAD - EXPEDITION TRAILER - 200tdi 90 BUILD THREAD - SANKEY TRAILER - IG@landroveranorak "You came in that thing? You're braver than I thought!" - Princess Leia |
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5th Oct 2019 6:09pm |
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