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blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17688

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

P38 pattern diff overhaul

Can anyone point me to, or send me, a manual covering the overhaul of the P38 pattern diff as used on the TDCi back end (even the 2-gear RR version would do) please? Specifically I am after the method and data for setting the pinion height and pinion bearing preload after fitting new pinion bearings.

The various manuals I have or can find cover removing and refitting the pinion housing from/to the axle but not overhauling it.

Having rebuilt my old ATB I wish to rebuild an ex-P38 RR 2-gear diff I have with the ATB to pop in the back end.

Many thanks.

11th Mar 2014 7:54pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2462

2007 Defender 110 Puma 2.4 SW Chawton White

I just did mine couple of weeks ago (Rear ARB and front trutrac). If you did not change the P&R, then you should not worry about the pinion height. As for pinion preload, it should turn at a 10Nm ish. Anyway, if you are interested send me a pm and I´ll send you a pdf file. Puma 110" SW

.............................................................
Earth first. Other planets later

11th Mar 2014 8:33pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17688

I was planning to renew (or at least inspect) the pinion bearings while I was at it. I believe the P38 uses shims for pinion height and a crush tube for preload, but was hoping for data. Apart from this it is all plain sailing.

If need be I'll leave the pinion alone and hope for the best.

11th Mar 2014 11:07pm

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2462

yes, it uses 64mm diameter shims for height and a spacer (not crushable at least on mine) for preload. If new bearings are not exactly the same as before you might have problems with preload. In my case I used a 0.2mm shim for getting a proper preload. The right way should have been to use a 0.2mm longer spacer but I could not get one. Puma 110" SW

.............................................................
Earth first. Other planets later

11th Mar 2014 11:57pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17688

Thanks. As long as it doesn't use a crush tube (horrible bodgy things) it should be ok.

Bearings are generally made to very fine (and graded) tolerances so existing shims etc shouldn't be far out.

Thanks again for your help. P38 diff info seems hard to find.

12th Mar 2014 12:43am

MK

Member Since: 28 Aug 2008
Location: Santiago
Posts: 2462

If it is for your 110 " Puma I have the info but I need you email to send it. Puma 110" SW

.............................................................
Earth first. Other planets later

12th Mar 2014 12:50am

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17688

I have sent you a pm. Thanks.

12th Mar 2014 1:16am

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