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2004 Disco 2 Engine Rebuild

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  #391  
Old 03-20-2021, 10:03 AM
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Driver’s side out. Took about 45 minutes. Busted a ratchet and thought “That’s a bad omen.” But it actually went rather smooth. Now on to the passenger side.


Not a good sign



 
  #392  
Old 03-20-2021, 10:23 AM
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Second one came out a bit easier now that I know what I am doing.


 
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  #393  
Old 03-20-2021, 11:32 AM
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Rear diff out!




 
  #394  
Old 03-20-2021, 12:52 PM
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Got the rear diff in. Had problems at first but disconnected rear passenger sway link and that gave me enough room to get it in there. That thing is a beast at 70-75lbs and it’s hard to move around in such a small space. Used a Jack and a strap to make it easier but in the end I had to manhandle it into place. Hopefully I didn’t mess up the rtv too much. Time for a beer!

Adding the weight to the new diff


Success!

 
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  #395  
Old 03-20-2021, 01:51 PM
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Pretty Green, I can see how that would tough to get in.
 
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  #396  
Old 03-20-2021, 03:17 PM
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Six hours taking my time and I am done. Beer-thirty. Still got to add some 1” spring spacers but that is a separate job I will take on tomorrow.

Thanks to @Alex_M for the excellent write up!


 

Last edited by cvhyatt; 03-20-2021 at 03:36 PM.
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  #397  
Old 03-21-2021, 10:43 AM
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Originally Posted by cvhyatt
Second one came out a bit easier now that I know what I am doing.

This picture brings back fond memories of my early days as a mechanic. Whenever we'd hire a new mechanic and get into brakes, long before knock-off drums, and the axle shafts had to be pulled to remove hub/drum assembly...we'd wait...and when new guy had pulled shafts and would step away from the job and wasn't looking...we'd switch axle shafts from one side of the vehicle to the other. We had to stop doing so, because this younger generation had no sense of humor and considered it a hate crime, or crime against humanity (can't remember which...that's what happens to a "boomers"...lol) and wanted their mommy's.
 

Last edited by The Deputy; 03-21-2021 at 01:11 PM.
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  #398  
Old 03-21-2021, 11:30 AM
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@The Deputy Too funny! I had to stop and take a second look at the axles to remember their position. I was afraid one of my kids was going to move them around when I wasn’t looking and then the job would have taken me 12 hours instead of 6. I am amazed I was able to put this thing back without screwing something up.
 
  #399  
Old 03-21-2021, 03:36 PM
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Added the 1” spacers to the rear, filled up the diff and took it for a test drive. No weird noises, leaks or smells. Next weekend I will do the same to the front end.


Spacer installed

Jack on the axle to give me room for the spring with the added spacer.

Fill ‘er up!

Decided to replace the plastic plug with something a bit more durable

Back end a little higher with the spacer. Time to upgrade to 33’s?
 
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  #400  
Old 03-22-2021, 09:22 AM
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looking good! 33s pending wheel offset (I'm not familiar with the 18" wheels) may cause some rubbing at full flex, the steel 16" wheels can require some trimming pending the condition of your springs and shocks
 
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