 | Home > Puma (Tdci) > Output shaft failure, Forum Survey |
 
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| MK Member Since: 28 Aug 2008 Location: Santiago Posts: 2407   
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In theory, you would need to use a lathe to cut a "groove (?)" for both sides of the boot and fit some sort of clamp, etc. By then, it may be wiser just to fit an aftermarket solution (Time and funds dependendt). Puma 110" SW
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4th Feb 2024 1:26pm |
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| Dinnu Member Since: 24 Dec 2019 Location: Lija Posts: 3403  
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Finding a CV boot with large diameter of 80mm should not be a problem. But a small diameter that fits on 40mm drive shaft would be. Perhaps you can carefully cut a smaller one along one of the bellows to get the 40mm shaft size.
The grooves are required on actual CVs to prevent the boot from coming out on a full steering lock. Probably would not be needed in this application. But what was remarked and also confirmed about the hydraulic pressure of the grease pushing the shaft out is more worrying. Perhaps it is smart to think of a more positive locating of the shaft in its cup and not rely on the snap ring pressure only. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing 2012 90 CSW, 2.2TDCI, Santorini Black |
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4th Feb 2024 2:20pm |
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| spudfan Member Since: 10 Sep 2007 Location: Co Donegal Posts: 4636 
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2008 2.4 Puma still on original factory fitted shaft. 210,403 kms.
2011 2.4 also still on original shaft at 103,372 kms 1982 88" 2.25 diesel 1992 110 200tdi csw -Zikali 2008 110 2.4 tdci csw-Zulu 2011 110 2.4 tdci csw-Masai |
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15th Feb 2024 12:43am |
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| Learningasigo Member Since: 30 Nov 2023 Location: Midlands Posts: 28  
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2014
2.2 110 xs Original shaft until Jan 2024 Failed at 80,000k LOF fitted |
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31st Mar 2024 7:42pm |
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| JPE Member Since: 19 Nov 2018 Location: South West England Posts: 333 
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2013 2.2 110 SW
Original shaft until April 2024 Failed at 99,000m On the basis the first one lasted 99,000 miles, I decided to stick with a standard shaft, but ... wait for it, this is complete genius and will blow your mind! ... with grease! It cost me £80 for a lorry to move it & £600 for parts and labour. Photos show the usual problems...  Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge |
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19th Apr 2024 12:36pm |
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| Dinnu Member Since: 24 Dec 2019 Location: Lija Posts: 3403
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^^^^ it looks like the shaft spent most of its life not fully into the cup. You can see where the splines did not wear where the snap ring should had been. Maybe you would had got a few extra miles if it was properly assembled (or not?).
Edit: Seeing the last photo of the cup splines, it looks like Landrover installed it correctly as there is some wear on the inner part of the splines, but somehow the shaft came out. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing 2012 90 CSW, 2.2TDCI, Santorini Black |
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19th Apr 2024 1:04pm |
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| JPE Member Since: 19 Nov 2018 Location: South West England Posts: 333
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Thanks Dinnu, I had wondered whether that wear pattern was normal or not.
Perhaps its been apart before & not reassembled properly - ? There are always so many mysteries to ponder when you have a defender. |
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19th Apr 2024 3:28pm |
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| MK Member Since: 28 Aug 2008 Location: Santiago Posts: 2407
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I have seen several cases where the adapter has made its way out of the female "cup". Puma 110" SW
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19th Apr 2024 11:30pm |
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| Ianh Member Since: 17 Sep 2018 Location: Essex Posts: 1972
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To be fair, inadvertently making our way out of the female cup has happened to all of us at some time. Next time I will blame it on JLR
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20th Apr 2024 12:36am |
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| MK Member Since: 28 Aug 2008 Location: Santiago Posts: 2407
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Puma 110" SW
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20th Apr 2024 1:34am |
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| spudfan Member Since: 10 Sep 2007 Location: Co Donegal Posts: 4636
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From my home mechanical experience, regarding the female cup. Up to a certain "milage" things fall out of the cup, after that they seem to flow out. Seems milage and age affects the rigidity and suppleness of the structure. Ah the old days when everything was a snug fit.....
 1982 88" 2.25 diesel
1992 110 200tdi csw -Zikali 2008 110 2.4 tdci csw-Zulu 2011 110 2.4 tdci csw-Masai |
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20th Apr 2024 9:22am |
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| ralsim Member Since: 16 May 2024 Location: wales Posts: 5 
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2014
2.4 110 xs double cab Original shaft until May 2024 Failed at 158,000miles LOF heavy duty will replace it current daily defender puma 110 xs 2.4 Current Project Series I 1.6 2 door past landrover 110 1983 v8 stage 3 engine with ported heads, ported polished inlet manifold balanced crank, large trumpets, top hat liners large valves ported plenum with large butterfly sadly stolen Last edited by ralsim on 17th May 2024 4:16am. Edited 1 time in total |
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16th May 2024 2:53pm |
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| LJMARSDEN Member Since: 08 Jun 2021 Location: Nottingham Posts: 325 
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brilliant 4.0 V8 Defender 90
My Instagram |
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16th May 2024 3:11pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17319 
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One-and-a-half MILLION miles !  I presume that is a typo? |
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16th May 2024 5:25pm |
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