Differential Rebuild Thread
That's brutal
lol
It's not easy to find non rusty parts in the rust belt. Must be easy in the sunny south
Do you guys know if an XJ40 diff would work?
lolIt's not easy to find non rusty parts in the rust belt. Must be easy in the sunny south

Do you guys know if an XJ40 diff would work?
I HAVE A BRAND NEW DIFF SITTING IN MY GARAGE WE MIGHT SOMETHING OUT WITH. iTS A 3.54 OR 8 I DONT REMEMEBR BUT ITS A YELLOW RED STRIPE AND BLACK X WHICH IS POWER LOCKED AND IS WHY I BOUGHT IT 10 YRS AGO. PART NUMBER JLM 162401 IF YOU WANT TO RESEARCH THE PART NUMBER. WHATS YOUR SPLINE COUNT?
I HAVE A BRAND NEW DIFF SITTING IN MY GARAGE WE MIGHT SOMETHING OUT WITH. iTS A 3.54 OR 8 I DONT REMEMEBR BUT ITS A YELLOW RED STRIPE AND BLACK X WHICH IS POWER LOCKED AND IS WHY I BOUGHT IT 10 YRS AGO. PART NUMBER JLM 162401 IF YOU WANT TO RESEARCH THE PART NUMBER. WHATS YOUR SPLINE COUNT?
What a bummer. So, I'm about ready to give up on this "quest" at least for now. I need this car on the road pronto. I found a stock diff out of an '03 XJ with 45,000 miles. I can have it Monday for $285. I don't know how long it will last thou.
Pictures of my XJ40/X300 'Power-lok' I'm intending to strip:



It's a 15 HU unit. The backing plate indicates it's a 1988 unit and the tag says 3.58 ratio.
I intend to replace both the crown wheel and pinion for a Dana 44 section and possibly the carrier for an LSD unit also.
I have zero interest in reflashing my tcm to make the car into a buzz-bomb on the motorway.
I still have to look into how to tackle the jurid coupling affair as the replacement dana 44 units are intended to place the earlier 4HU units with U joint.
I personally wouldnt touch the weak 14 HU X308 unit now. If I were sticking with that I'd reinforce/shot peen the gears. It seems to be the pinion that fails, I believe it has on my old one too, although I havent stripped it yet.



It's a 15 HU unit. The backing plate indicates it's a 1988 unit and the tag says 3.58 ratio.
I intend to replace both the crown wheel and pinion for a Dana 44 section and possibly the carrier for an LSD unit also.
I have zero interest in reflashing my tcm to make the car into a buzz-bomb on the motorway.
I still have to look into how to tackle the jurid coupling affair as the replacement dana 44 units are intended to place the earlier 4HU units with U joint.
I personally wouldnt touch the weak 14 HU X308 unit now. If I were sticking with that I'd reinforce/shot peen the gears. It seems to be the pinion that fails, I believe it has on my old one too, although I havent stripped it yet.
I was in the same situation. Got really fed up of the Jag and left it in the corner. Using the truck to go into work. Now my wifes Mercedes transmission is slipping. Another project! Still working on the Challenger rebuild and I'm buying a 1980s BMW M635CSi next week- too many projects!
I was in the same situation. Got really fed up of the Jag and left it in the corner. Using the truck to go into work. Now my wifes Mercedes transmission is slipping. Another project! Still working on the Challenger rebuild and I'm buying a 1980s BMW M635CSi next week- too many projects!
Honestly, when I took apart the Jag HU14 i believe the main issue with those diffs is that they are poorly set up. The teeth on the Pinion stripped right at the tip which leads me to believe that the contact patch on the gears wasn't optimally set up.
As far as your Jurid coupling issue, since you have the early XJ40 rear with the 10 splines, I'd just take the 4 hole flange and re-drill it with 3 holes if your new pinion gear will have 10 splines. Sounds like a piece of cake
I'm in the same boat, minus I don't have a truck and I don't think my GF would be to thrilled with me picking up another car. My Mustang needs a t-5 rebuilt and main bearings at least. My 911 is paralyzed also due to a differential issue pertaining to a pinion bearing ($500 part) and now the Jag.
Honestly, when I took apart the Jag HU14 i believe the main issue with those diffs is that they are poorly set up. The teeth on the Pinion stripped right at the tip which leads me to believe that the contact patch on the gears wasn't optimally set up.
As far as your Jurid coupling issue, since you have the early XJ40 rear with the 10 splines, I'd just take the 4 hole flange and re-drill it with 3 holes if your new pinion gear will have 10 splines. Sounds like a piece of cake
Honestly, when I took apart the Jag HU14 i believe the main issue with those diffs is that they are poorly set up. The teeth on the Pinion stripped right at the tip which leads me to believe that the contact patch on the gears wasn't optimally set up.
As far as your Jurid coupling issue, since you have the early XJ40 rear with the 10 splines, I'd just take the 4 hole flange and re-drill it with 3 holes if your new pinion gear will have 10 splines. Sounds like a piece of cake

My 15 HU diff has the 3 hole flange just like the 14 HU but when I insert the Dana 44 bits it will be more like an EARLY unit, so perhaps what you say would work. I'm trying to find my tools right now, (since I moved from Cali I lost alot of stuff) could do with more space to work
My wife is worse than me, she wants more and more old cars! She wanted a series 1 XJ12 but I convinced her that the M635 CSi was a more usuable classic.
My 15 HU diff has the 3 hole flange just like the 14 HU but when I insert the Dana 44 bits it will be more like an EARLY unit, so perhaps what you say would work. I'm trying to find my tools right now, (since I moved from Cali I lost alot of stuff) could do with more space to work
My 15 HU diff has the 3 hole flange just like the 14 HU but when I insert the Dana 44 bits it will be more like an EARLY unit, so perhaps what you say would work. I'm trying to find my tools right now, (since I moved from Cali I lost alot of stuff) could do with more space to work
I'm a big fan of the 635CSi too
My GF doesn't mind my car hobby since I maintain all the cars for us and her business, but we're in the middle of remodeling and that is eating into my car mod budget.
Let me know the part# on that flange or how much you want for it. I might be interested if I find one for a good price with the wrong flange. Post some pics of it if you can. Where did you source that diff if you don't mind me asking?
I'm a big fan of the 635CSi too
My GF doesn't mind my car hobby since I maintain all the cars for us and her business, but we're in the middle of remodeling and that is eating into my car mod budget.
I'm a big fan of the 635CSi too
My GF doesn't mind my car hobby since I maintain all the cars for us and her business, but we're in the middle of remodeling and that is eating into my car mod budget.I got the diff from a friend in Michigan.
I maintain all of our cars too. My wifes used to American stuff and I'm showing her that Euro stuff doesnt have to be expensive- except im having difficulty showing her this right now
This is a picture of the flange end of the diff.
I cant see the part numbers yet, when I get some better day light...

There is a place in Western Michigan that does fully refurbed units but they usually ask for about a grand as does Coventry West.
These guuys seem to do older diffs also-again not cheap
Jaguar Remanufactured Differentials
I cant see the part numbers yet, when I get some better day light...

There is a place in Western Michigan that does fully refurbed units but they usually ask for about a grand as does Coventry West.
These guuys seem to do older diffs also-again not cheap
Jaguar Remanufactured Differentials
My first proper car was a 633csi Alpina.
I lent it to my father, who was collecting my sister from going horse riding. On the way home along a country lane, someone had dumped a skip outside a house on a bend. As the family approached, a wagon pulled out and blocked the road. The car landed on to of a field full of sprouts. Nothing wrong with either passengers or car. I guess they built them strong!
I spent every penny I earned on it, updated the front bumper/spoiler and lights to the later 635 along with the 5 speed gearbox.
I think the early Karmann cars were the best looking because of the low roofline. I'd have put the M engine in but couldn't find one. Sold it to buy a van for work, I really wish I hadn't
A nailed on classic the M, very rare here in the UK now, blame that on the salt roads. Only the XJS is comparable of that era.
I lent it to my father, who was collecting my sister from going horse riding. On the way home along a country lane, someone had dumped a skip outside a house on a bend. As the family approached, a wagon pulled out and blocked the road. The car landed on to of a field full of sprouts. Nothing wrong with either passengers or car. I guess they built them strong!
I spent every penny I earned on it, updated the front bumper/spoiler and lights to the later 635 along with the 5 speed gearbox.
I think the early Karmann cars were the best looking because of the low roofline. I'd have put the M engine in but couldn't find one. Sold it to buy a van for work, I really wish I hadn't
A nailed on classic the M, very rare here in the UK now, blame that on the salt roads. Only the XJS is comparable of that era.
Last edited by Sean B; Mar 4, 2012 at 05:54 PM.
Sean this was my first car
My First Car: BMW 323i
An E21 BMW 323i. I still own it and it's being ground up rebuilt in the Netherlands right now. I always lusted after the 6 series. Came close to owning one a couple of times, in the UK I got a Porsche 928 S4 instead and in Germany I found I couldnt afford one due to their taxation based on emission class (read age of vehicle) and engine size. Now over here I know i'll regret it if I dont get this one before the prices rise. It's also a non cat Euro car.
The old school BMWs were quite simple cars, their suspension systems were very simple compared to Jags and the SOHC engines were robust, durable and simple also. Lots of space to work around the straight six. Fabulous imposing styling. THey were simple cars but in terms of engineering science of breathing and thermodynamics, everything was typical BMW: executed perfectly! I miss that about BMWs today
My First Car: BMW 323i
An E21 BMW 323i. I still own it and it's being ground up rebuilt in the Netherlands right now. I always lusted after the 6 series. Came close to owning one a couple of times, in the UK I got a Porsche 928 S4 instead and in Germany I found I couldnt afford one due to their taxation based on emission class (read age of vehicle) and engine size. Now over here I know i'll regret it if I dont get this one before the prices rise. It's also a non cat Euro car.
The old school BMWs were quite simple cars, their suspension systems were very simple compared to Jags and the SOHC engines were robust, durable and simple also. Lots of space to work around the straight six. Fabulous imposing styling. THey were simple cars but in terms of engineering science of breathing and thermodynamics, everything was typical BMW: executed perfectly! I miss that about BMWs today
Most of the time I am driving in normal mode even. The higher you go in engine power the more optimization you can use, but that’s something you will find out once you are there yourself. Also remembering you where planning to up the rpm, you would need to tune your TCM for that.
So if you want a buzz bomb, you need to up power and change your gear ratio, as that will not happen with a TCM tune.







