Hi, i use this site every weekend to solve my Discovery issues but no such joy this time so I thought I’d join and ask.
Couple of weeks ago went off-roading and the rear diff **** itself, drove home without the rear half shafts in with handbrake on but only made it 10 minutes until it clunked to a halt and smelt very warm.
I put a new diff in the rear aswell as new bearings etc and went for a test drive. When setting off, maybe 20% of the time, I get a loud clunk, like really loud, as though it’s slipping a spline or a gear, then it will drive perfectly. Only does it setting off.
My Landy has 33’s and +2 lift, I am a bit meticulous when it comes to repairs, so it has all the oils and greases changed recently, new bearings all round and on the diffs, new ujs on both props, recent clutch.
Everything seems to be tight bush’s wise so I think it’s more internal, I thought I’d ask for opinions before I take drastic measures and it isn’t what I think.
many thanks

 

the handbrake was holding the rear drive shaft while you were driving. It would have been better (obviously with hindsight) to pull the drive shaft also.

The handbrake is just a drum brake on the rear drive shaft.

I'd look at the rear output of the transfer case and the drum brake for the handbrake for clues.

 

Bearmach Trailfitter videos are a good resource for troubleshooting Rover TC and axles.

 

Clunking and knocking probably a cranshaft bearing failure