Megasquirt V8 - Land Rover Pegged Differentials for Ultimate Strength

If you're thinking or you already are running a upgraded Differential, whatever it might be, you will have, or will be spending a significant amount of money on your Differential.

Add a Heavy Duty CW&P and that investment could easily reach £1000ish, possibly £2000 if you do both Differentials.

Then there's Heavy Duty shafts and so on. Not Cheap. Even a Second Hand 'Locker' of some flavour in Good Condition will be circa £600+

And then it can all go of so horribly horribly wrong, and your expensive Differentials can be seriously damaged or even destroyed in a split second Off Road ..

Why ? How ? And what can you do to both increase the Strength & Protect your investment ?

It's very common for either Standard or Upgraded Heavy Duty CW&Ps to loose 'Tips' and bits of their teeth when used hard off road. The slightest chip not only means the CW&P has had it, but those 'Chips' can them move into the Differential Centre itself, doing secondary, often severe even terminal damage.

In your Land Rover Differential the Pinion is in effect doing a 'Corkscrewing' movement against the Crown Wheel, as it does this it's really trying to 'Push' the Crown Wheel away from the Pinion. With heavy torque & shock loadings this effect can in an instant magnify enough for the mesh of the Pinion & Crown Wheel to move apart, riding up the root tooth, at this point for a fraction of a second the teeth are being driven on their 'Tips', and as these are weak they break away.

Very often on the return of the Pinion & Crown Wheel to full mesh additional damage is incurred. These case hardened broken bits of teeth are now all lonely and going looking for friends to play with ...your expensive Differential Centre being both close and the most attractive.....

"Pegging" the Land Rover Differential Casing increases the strength of the Differential via the special modifications we carry out in house (we make our own 'Pegged' Casings) massively, by ensuring once fitted a constant contact and full mesh of the CW&P is maintained at all times.

The Pinion is 'Locked' into mesh it once 'Pegged' . It now cannot push the Crown Wheel away from the Pinion, or the Differential Casing flex to allow it 'tooth climb' break away and do the damage.

This is achieved by 3 x CNC Laser Cut Plates, Specially TIG Welded to the Differential Casing, heavily machined, Drilled & then Tapped and fitted with Special '12.9T Dog Bolts'. We make ALL our own assemblies, TIG welding them ourselves. As at May 2017 we are pretty much nearly at Number 345, and without a single failure to date !. See top picture and video of our work.

These are engaged through the modified Pegged Casing on the new 24mm threaded steel assembly which has been TIG welded in place, with a special CNC Phosphor Bronze Slipper pad correctly set up on the rear face of Crown Wheel. .

The Pinion is 'Locked' into mesh it once 'Pegged' . It now cannot push the Crown Wheel away from the Pinion, or the Differential Casing flex to allow it 'tooth climb' break away and do the damage.

This is achieved by 3 x CNC Laser Cut Plates, Specially TIG Welded to the Differential Casing, heavily machined, Drilled & then Tapped and fitted with Special '12.9T Dog Bolts' which are engaged through the modified Casing on the new 24mm threaded steel assembly TIG welded in place, with a special CNC Phosphor Bronze Slipper pad correctly set up on the rear face of Crown Wheel.

With a 'Pegged Differential' the only way the CW&P Can fail is to actually physically tear the Crown Wheel Teeth clean off the base plate of the Crown Wheel, possible but very very rare, change the CW&P set for a Heavy Duty unit and then you really have a strong unit !. (Picture Bottom Right!)

See the Video which shows exactly the efforts taken to actually make a Megasquirt V8 'Pegged Casing' from start to finish : See Video as to how we make these and what goes into the conversion