I have a friend with an XJS that has the Dana diff. While replacing rotors, he managed to strip the 3 output shaft studs that hold the rotors on.

I understand from this useful thead....

https://www.jaguarforums.com/forum/x...tified-229645/

......that the output shafts are built up with shims etc, and buying a whole assembly is the way to go. No one seems to have these, so he's looking at options.

There are lots of GKN diffs around, and imagine they are a straight swap. It looks like a matching driveshaft would be needed too, since the diff input flange is different.

Any thoughts?

Thanks,

Rob

 

I'm confused. There are 4 studs that hold the rotors on, and also mount the half shaft to the output flange/brake rotor/camber shim pack sandwich on each side. Those studs are replaceable without removing the output assembly from the differential. Are those the studs you are talking about? If not, what three studs are you talking about?

A Salisbury diff will bolt in; I've done it recently. No change in drive shaft or half shafts is necessary. Different brake rotors are required to access the caliper mounting bolts which go in from the opposite side on a Salisbury vs a Dana. Of course you'll need to remove the complete IRS from the vehicle, and reshim the fulcrum mounts that bolt to the side of the diff.

Jon

 

Jon, thank you.

To clarify, the guy stripped 3 of 4 studs that go through the rotor and halfshaft.

I've never replaced studs on a Dana, and it appears from the pictures in the above link, that you would not be able to punch out the old studs without the output shaft assembly being disassembled. The studs would hit the flange that bolts to the diff.

The post suggests that dissassembly of these is not straight forward like the GKN.


It's good to know that a matching driveshaft is not needed.

I hope there's a way to save this guy.

Rob

 

It's hard to tell from those pictures if the stud would clear the flange and be able to be knocked out. Maybe they can be, and that's why the head of the stud is round?

If so, I could grind down the head of a GKN bolt?
Thanks,
Rob

 

I've removed all of the studs while the diff is in the car within the last 6 months. You can clock each stud to a position where the head of the stud will just clear everything, and can be removed. An air chisel with a hammer bit will make the job of driving out the old studs much easier.

Jon

 

The hard part may be to find new studs that fit. They aren't listed in the parts manual, but I think I've seen them for sale somewhere. I'd call Coventry West and see if they can help.

 

Phew! That's a relief!

Yes, the good people at Coventry West may be able to help.

Thank you!!

Rob