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MG TD TF 1500 - Reconstructing the differential

I was unlucky enough to break a axle shaft a few weeks ago. I have had to take apart the differential to all pieces out. Any helpful hints before i put this back together? I know I need to soak the differential gasket in water, anything else? I have Tom Lang axles that I am replacing the stock axles with
TR Hammond

Just for my own information, a few questions that might help me prevent this from happening to my stock engine TD. When this happened, were you pulling away from a stop? Shifting gears? Running uphill? Is your final drive ratio stock? Is your engine power enhanced? Total mileage on the car, if known? Sorry for all the questions but I have an interest in these failures. Good luck with your repair.
John Quilter (TD8986)

No problem. 82k on the car, someone stop quickly, I jammed the brakes and missed the clutch. Not uncommon. For someone not mechanical inclined, an easy job. Highly recommended Tom Lange axels.
TR Hammond

Make sure to place the bearing collars on the same side that they came out from. They control the back lash of the gears.

Butch
R Taras

The majority of axles break with one commonality: when maximum torque is sharply applied. Starting off quickly is one moment, but most torque is applied when taking off on a hill or a small incline, when you release the clutch quickly so the car does not roll backwards. You have the weight of the car working with gravity to turn the axles in one direction, and the torque of the engine twisting them in the opposite.

What people don't always know is the condition of the inner splines; over time and normal mileage, the stub can begin to twist, leading to eventual breakage, without warning. The only way to know is to remove the axles and check them from time to time, but even that is not failsafe - a stub can twist off without ANY warning, if enough torque is applied.

Remarkably, in all the years there has not been a SINGLE reported case of one of my Austin/Clark/MGT Repair axles breaking, even under racing conditions.
This is why many people install my improved axles, even before an incident. The time, effort, aggravation and repair costs are significant if an axle breaks.

Even when my supply costs increase, I guarantee my axles will ALWAYS be priced less than stock Moss axles, which lack all my improvements.

Tom Lange
MGT Repair

t lange

I would disassemble the carrier and look at the thrust washers. They are unobtainium but you may want to find another carrier to rob the them from.
W A Chasser

Final breakage is usually under the circumstances described above. However, when they actually break, leaving you without drive, most of the damage was already done. Except for rare circumstances, the axle was already cracked and/or twisted, as Tom said. Metal fatigue was already present even before that ..... waiting for the final event/s which finished the job.
I believe there are two things which can be done to help/delay/prevent axle breakage.
1 Fit proven, good quality axles such as Tom's.
2 Reduce the stress point by removing the sharp spline edges on the diff sun-wheels. Sharp spline edges cut into axles, creating stress raisers where fatigue and breakage occurs. If the ends of the parallel splines are gently splayed outwards, they will not cut into the axle, so will not cause such a bad stress point.
The images show an axle which has been cut into by sun-wheel splines, and offending, sharp edged sun-wheel splines
Bob Schapel






Bob Schapel

This thread was discussed between 06/08/2022 and 08/08/2022

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