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Discussion Starter · #1 ·
Hey guys & gals,
After trying to fix my rear coupler by changing out the bearing (and failing), I managed to find the part on Ali-Express for the crazy low price of $322 / £256 delivered from China to the UK.
6 weeks later and the part arrives. Really well packaged (NO damage to the package whatsoever).
Packing materials Orange Shipping box Amber Packaging and labeling

I opened it up and it really looks the business. Then I saw a flattened part of the gear housing that slips into the rear diff case.
Automotive tire Rim Gas Composite material Font
Bicycle tire Automotive tire Wood Rim Material property

On closer inspection, this has taken a fair whack and the steel is dented and cracked
Tire Automotive tire Wheel Road surface Asphalt


I've contacted the seller and they're adamant that the part is still good. I'm not keen on risking it to be honest, but they're reluctant to arrange a return due to shipping costs etc.

I know this section of the coupler remains stationary so there's no danger of it breaking further during use, but I'm concerned the inner gears may also be damaged from whatever impact caused the dent.

I've been offered a partial refund as compensation for the damage.
Should I accept that and try the part? Or stick to my guns, carry on in 2WD for another 12 weeks get it replaced?
 

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I think it could be trouble. It appears that's a sealing area so I'd expect it could leak fluid out of the clutches. Try your best to get another I think or get a full refund or as much as you can. How far did you dismantle the old one?

Line Font Gas Engineering Cylinder



Do you think you could fully dismantle both and use the old casing with the new one? at least you have the old one to practice disassembly before making a decision. You would want to save any fluid in there though I think this slide show may say what is the fluid.


I had a similar experience with a wrecking yard dropping a combined diff and coupler. Of course the coupler was te bit damaged. I did manage to make one good from the old one's case. Tat was for ix35 and the next type of coupler by magna Industries
 

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Discussion Starter · #3 ·
Thanks Gerard2. Really appreciate the slide show, that'll be a massive help.
I got as far as removing the coupling case and separating the clutch housing, but I haven't opened that up.
I'm a hobby mechanic at best and I'll need to wake up feeling extremely lucky before I crack that open, but it may be worth a shot as you say.
Those secondary clutch plates scare me. Do they need to be put back in alignment or would they readjust themselves once under load?
In the meantime, I'll keep negotiating with my Chinese friend.
Thanks again (y)
 

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No idea, I don't even know if it's wet in there or not but my philosophy is if you dismantle it and reassemble in the same order and orientation it should be fine. That's where the old one is perfect to practice on. I doubt they'll want it shipped back.

The clutch pack just needs to be kept together in order and put back in the way it came out. The steels lock into the hub and the clutches free spin until a clamping force is applied.

 

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This extreme garage site is excellent. I even sent a message to these guys confirming what fluid they used in the newer couplers, kindly responded with tips.

Worth looking at their other videos.

 

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I think I'd be insisting on a replacement, that looks like it'll leak.

I bought one from Amazon, it's working great. Has been in for several months now. It was about $600 cdn. Wouldn't surprise me if they all come from the same factory.

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Hey guys & gals,
After trying to fix my rear coupler by changing out the bearing (and failing), I managed to find the part on Ali-Express for the crazy low price of $322 / £256 delivered from China to the UK.
6 weeks later and the part arrives. Really well packaged (NO damage to the package whatsoever). View attachment 470953
I opened it up and it really looks the business. Then I saw a flattened part of the gear housing that slips into the rear diff case.
View attachment 470954 View attachment 470955
On closer inspection, this has taken a fair whack and the steel is dented and cracked
View attachment 470956

I've contacted the seller and they're adamant that the part is still good. I'm not keen on risking it to be honest, but they're reluctant to arrange a return due to shipping costs etc.

I know this section of the coupler remains stationary so there's no danger of it breaking further during use, but I'm concerned the inner gears may also be damaged from whatever impact caused the dent.

I've been offered a partial refund as compensation for the damage.
Should I accept that and try the part? Or stick to my guns, carry on in 2WD for another 12 weeks get it replaced?

Hi mate
I have just read your post about the coupler you bought from aliexpress. I think I have the same issue, thumping like crazy.
did your coupler work in the end? Would you mind sharing the link for the seller by any chance?
Also would a normal mechanic be able to fit this or is it a specialist job. I’m clueless with cars but would love to get this fixed as it’s driving me mad

thanks for your help
Neil
 
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