After Mahindra - Replacing Auto to Manual Locking Hubs, I realised the problem was a bit worse. The CV axle actually popped out from the diff. NO! Even worse, it actually snapped inside of the diff!
Diagnosing
I’ve got some tips from Plimmerton Motors. We tried to put it back without disassemble but didn’t manage to.
I removed way too many bits to be able to get the CV joint out, and received the bad news, it snapped inside of the diff. I now have to take it out. Let’s see how that goes… I will update this later
Later… Removing the axle from the diff!
500 hours of research in the webs and asking every mechanic friend you have about how to remove that bloody axle from the diff.
- Remove both hub assembly from Knuckle
- From top, remove locking pin, locking nut, smash it up
- Bottom, just unscrew 4 bolts without touching the locking pin and nut (way easier)
- Be careful with ABS sensor, you can unplug it
- Remove both CV joints
- Drain diff oil out
- Be amazed with Mahindra for using 3/8” for the draining plug
- Buy an adapter from 1/2” to 3/8”
- The bloody thing doesn’t fit!
- Build your own tool grinding a HEX key
- Remove 4 screws linking the shaft to the Diff (size 8 bolts)
- Remove bottom screw from both shocks (makes it easier to assemble everything later)
- Jack diff up
- Remove 4 screws keeping differential up
- Jack diff down, be careful for it not to fall, easier with a friends hand
- Had to move it form one side to another to allow it to slide off
- Look at the diff for 10 minutes feeling proud and overwhelmed
- Open diff front cap
- look for metal pieces using a magnet
- clean as much as you can using paper towels
- remove axle piece using a screwdriver
- show off time. take a nice picture
- remove diff seal
- clean up the front diff cap
- plenty of gasket stuff to make sure no water gets in the diff
- close everything up
- clean the outside and paint the top of it with underbody coating
- install the diff back to the car using the jack again
- install passenger side hub assembly in reverse order
- used jack to help compress the suspension
Parts challenge
I’ve got the quote back from Mahindra, and a new CV join (part number: 0504AAA00270N) costs staggering 2500 NZD. It’s strange, that from ebay, we can import the exact same Mahindra original part delivered for 390 NZD.
Good after sale support
I’ve got in touch with Mahindra NZ about my challenges, and they called me back assuring they are working hard to make the parts affordable and ready in stock. Sometimes due to air freight from India, the parts are listed for a higher price than expected. They personally made themselves available to help with any issues with the truck. I will keep Where to find spare parts Mahindra Pik Up in New Zealand updated after receiving new prices.
That would take too long to arrive. I was then saved by Steve from AgTorque Manawatu, which had a second hand CV Joint. It is still expensive 500 NZD, but was sent to me the next week.
Looking for parts? Check Where to find spare parts Mahindra Pik Up in New Zealand.
Finishing the job
I finished the installation without any issues, also changed the diff seal. I was tired and didn’t take much pictures… but the truck is finally back on the road!
Tip time!
After fixing something in your CV that may result in metal in your Diff, drive in 4wd (on straight lines), and do some corners (not on tarmac). Then replace the diff oil again to make sure all metal bits are off. Thanks to Roger from Plimmerton Motors for the tip
I’m not a professional, so I took the car for Plimmerton Motors to do a check on my job and everything looks fine.
References
Good tip to remove VS axle and put it back and out. https://www.youtube.com/watch?v=Qo4aeTEFGZs
Nice video explaining how to work on a CV Axle. Heaps of tips. https://www.youtube.com/watch?v=YH5Cf7uJV5Y