 | Home > Puma (Tdci) > Rear end loud bang when pulling away. |
 
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 1981  
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Unfortunately it does sound like the output shaft issue.
How many miles have you done as that guides you to the best output shaft replacement. If it’s low miles then it pushes you more to the Ashcroft solution. I’m afraid it’s going to be a circa £1k - £1.2k job if you get a good independent to do it as you might as well have the clutch replaced at the same time. |
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17th Jul 2023 10:24pm |
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| Ronniebee Member Since: 12 Oct 2015 Location: U.K. Posts: 31  
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Mileage is 78k and it’s a 62 plate.
Need to have a ring around today and get it in somewhere. As to the output shaft, I’m presuming it must have been very worn and me being gentle on the clutch and gear change due to the rear banging it survived until I put the new rear halfshafts in and gave it a bit more wellie. There’s enough in the Defender rainy day fund to cover it at £1500 I’m just hoping it’s not too much more. |
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18th Jul 2023 4:57am |
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| Retroanaconda Member Since: 04 Jan 2012 Location: Scotland Posts: 2637 
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£1,200 to remove a transfer box and put it back on? I’m in the wrong job!
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18th Jul 2023 5:05am |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 1981
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It’s a lot less if you don’t do the clutch as well. For instance a lof power spec kit comes in at circa £410 plus the additional labour to remove the gearbox, fit clutch and replace.
So if it’s just for an Ashcroft output shaft it’s circa £360 plus labour to get the transfer box out and replace shaft. I expect in total that would come out at circa £500 all in inc vat. If you are paying an independent to do the work It’s bit of a dilemma as to whether you change the clutch at the same time. Early 2.4 clutches did not last long, springs and slave cylinders generally being the issue, but the later ones and the 2.2 clutches seem to last a lot longer. So if you want to save some labour costs, avoid another trip to the Indy, and have a fit and forget solution for another circa 100-150 k miles then you can get it done all in one go. If you think the clutch has a lot more miles in it then you just go for the upgraded shaft replacement. |
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18th Jul 2023 10:35am |
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| Ronniebee Member Since: 12 Oct 2015 Location: U.K. Posts: 31
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Great info on this, thank you.
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18th Jul 2023 11:17am |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 1981
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For the output shaft you have a few options on the market.
1. Replacement Standard shaft with good grease. Cheapest but that’s what’s lasted 78k miles, not bad but not great. Circa £175 2. Ashcroft solution, oil fed coupling, the latest versions have had great reports, should last much longer than 78k miles, probably best if you have a bit of misalignment as you seem to have. But Indy does need to know how to fit correctly to ensure oil tight fit. Circa £360. 3. LOF single piece extreme output shaft, great solution but could pass on misalignment stresses to other components, also clamping force to gearbox is less so could potentially cause issues there. However no reports so far on any of those potential issues arising and several members have fitted and very happy. Circa £355 4. IRB HD Adaptor Shaft Kit. A two piece kit , connects to the gearbox in standard way with same bolt and torque. However the two components are not connected by splines , instead they bolt together to make it like a single piece solution. This is the newest solution, looks good from an engineering point of view but like the LOF solution could pass on misalignment stresses to other components. Circa £396. Edit- originally stated £296, my typo, should be £396, now corrected. In your position with failure at 78k miles my head would say Ashcroft, however my heart would push me to IRB. How comes ? Well Ashcroft treats the symptoms and may last a lifetime, but involves seals so they may need replacement at some point, IRB treats the cause but could pass on misalignment issues to other components, however given you have done 78k miles on the old shaft the misalignment may not be significantly large enough to overly stress other components. It all depends on how risk averse you are and which risks you are more adverse to. Last edited by Ianh on 18th Jul 2023 7:29pm. Edited 1 time in total |
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18th Jul 2023 3:24pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17343 
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Why do you say IRB treats the cause? None of them aligns the boxes, the most likely root cause of the problem.
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18th Jul 2023 4:50pm |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 1981
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A good point BW, it’s not a perfect use of words. What I mean is a combination of the misalignment and the LR design with splines results in the failure. I.e if LR had designed an output shaft solution that was more tolerant to misalignment then we would not have had this issue or it would have been much reduced.
The Ashcroft solution seems to treat the symptoms of the above by providing good constant lubrication to the splined design, the IRB solution removes one of the components of the cause, the spline element. so in my mind IRB is treating the cause, which as I see it is not one thing (misalignment) , but two things ( misalignment plus the LR output shaft designs inability to cope with misalignment ) However it does have a potential downside as it may pass the failure onto other more expensive components. |
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18th Jul 2023 6:18pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17343
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18th Jul 2023 6:55pm |
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| Ronniebee Member Since: 12 Oct 2015 Location: U.K. Posts: 31
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Thanks, I booked it in earlier today and they mentioned the LOF part and I agreed to go with it. |
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18th Jul 2023 7:17pm |
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| Ronniebee Member Since: 12 Oct 2015 Location: U.K. Posts: 31
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Well I picked the 90 up today and it’s job done using the LOF part.
What a difference, no more slack and clonking. Thanks for all the helpful comments everyone. |
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24th Jul 2023 4:03pm |
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| lonewolf Member Since: 23 Oct 2013 Location: North East England Posts: 209 
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Did they show you the original output shaft that they removed? Were the splines shredded?
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24th Jul 2023 4:24pm |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 1981
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If you are happy to share.. what was the labour cost...or labour hrs to do the job ?
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24th Jul 2023 4:57pm |
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| Ronniebee Member Since: 12 Oct 2015 Location: U.K. Posts: 31
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5.5 hours, the transfer box linkage was included in the repair.
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24th Jul 2023 5:59pm |
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