Diff Suggestions for my KJ 2.5CRD

[indiedog]

Hi All. I've had a nice noise in the rear diff for a while and today had it looked at by a gearbox specialist. The main bearing is shot so needs replacing. It's then a lucky dip as to the condition of the crown and pinion gears which could be just lapped if they are okay or may need replacing. Sums are as follows;

Labour to remove and replace rear axle/diff - $350
Full service to diff including bearings, seal etc - $850
Lapping to existing crown and pinion gears if okay - $250
Replacement crown and pinion if not okay - Ballpark of $1200

So at best it's $1450 and at worst (hopefully) it's $2400.

A mate of mine said why don't I just go get an air locker instead? I called ARB who quoted $1600 for the locker (model RD93) plus $550 for the compressor all fitted. On top of this I would have to replace the bearings (not sure of cost) but overall quite competitive. Only hassle is they won't have any in Australia until late August and I'd have to hope my diff holds out until then. Obviously it would be better to get the work done now if I'm going to potentially reuse the existing crown and pinion.

Are there other options for this? Who else would make a diff for a 2.5CRD KJ? Apparently it's the same diff as that used in the XJ so I gather it's fairly common.

Thanks for the input. Indie.

[indiedog]

Got a price for a bearing and seal rear diff kit from the guys in Hervey Bay for $270 so that would need to be added to the air locker price. If that's the price for the parts then $850 doesn't sound cheap for the diff refurb.

[Pipeliner]

Even if you get a locker you'll still have to sort out the crown wheel and pinion.

[glend]

Is your quote from Hammonds? If not I'd call them. They do this sort of work and know Jeep diffs (its just the Corporate 8.25). You need at least two or three quotes to get a good idea of whether they saw you coming (if you know what I mean). Don't buy the ARB locker unless you really think you need it, most KJs can get along without them - even on the Old Telegraph Track.

[indiedog]

Yeah, in educating myself on what's involved I learned that the original crown and pinion and all the bearings and seals were just reused when you install a locker. So by the time I allow for all of that to be refurbed I'm looking at $2650 for the locker option plus extra labour. And that's if the crown and pinion can be saved with a lap. So at this point I'll just go for the straight diff service at a minimum of $1450.

I did call Hammonds and they said allow $1800 and I'd be waiting around 3 weeks to get in. The quote I got is from Gabba Gearboxes. Pretty good to deal with so far.

Question. What ratio diff is standard in the 2.5CRD? The guys in Hervey Bay need to know this or a part number to get me a price for crown and pinion. And is it worth getting the wheel bearings done at the same time or are they a simple replacement later?

[senatorjohn]

Don't know the diff ratio for the CRD but the petrol is 3.78 I think. Jack the rear up and rotate the tail shaft 3.75 times and see how far the wheels rotate provided the rotate at the same rate together. If you have LSD, they definitely will. If have not rotated a full revolution , try 4 revolutions to see if you have a 4.1 (I think) ratio.
John

[DarrenR]

Just some added info....

*Dana diffs, the ratio is stamped on the crown wheel as two set of numbers, a small number and a large number, divide the small number into the large number, thats the ratio.

*(while this doesnt help you) In Perth I use (as do a lot of repairers) Brian "The Diffman", he is without a doubt "the man" when it comes to Jeep & diffs, Its pretty rare the crown wheel and pinion needs replacing. New bearings and then set the diff up again until the bite is correct. The "lapping" sounds like they are having a lend of you, personally I think the prices quoted are over the top.

Brain charges $250 labour, plus cost of bearings, say another $250, I add another $250 on that (its done in my workshop, fluids, and I do the monkey work), thats only $750...... big diff from $1450 - $2400.

Regards
Daz

P.S Again in Perth, SBR Offroad can supply the Crown wheel & pinion set which is complete with bearings I thought from memory, and I think round $600 for the kit. They prolly even do shipping, does anyone from sbr offroad come on here?