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lrmaniac

Member Since: 04 Feb 2010
Location: Lisboa
Posts: 762

2010 Defender 110 Puma 2.4 DCPU Keswick Green

blackwolf wrote:
I learned today from a senior tech at a main dealer that there is now an official mod consisting of reworked parts to address this problem. The internally-splined cup which attaches to the gearbox output spigot now has two diametrically-opposite grease nipples, and the extension casing has a hole in the bottom directly beneath the nipples. The idea is that by turning the output shaft until the nipples are vertical and inserting a greasegun through the hole, the assembly can be greased. Low-tech but probably effective.

Oficial, as in LR service bulletin? Or instructions to the dealer on how to do that "DIY" job? Can't we get a copy of that sheet?

The nearest oficial dealer here, never heard of such failure! Regards
Joao

'10 Land Rover Defender 110 CC
'08 BMW F800GS
'64 SIIA Forward Control
'69 SIIA 109 ZA CKD
_____________________________________________
You have the right to remain silent. Anything you say will be misquoted, then used against you.

8th Dec 2013 12:26pm

Phantom

Member Since: 29 Jan 2013
Location: Isle of Wight
Posts: 136

Well when I ordered the box from ashcroft they new all about the issue, my understanding is its a well known fault

8th Dec 2013 6:00pm

munch90

Member Since: 26 Oct 2013
Location: guildford
Posts: 3558

Took my transfer box out this afternoon ..bit of brown dust around spline but no wear .but very dry so packed with grease and put back together ( prevention is better than repairing after the spline gone and it's cheaper ) didn't take long to do . Found front output flange leaking a bit ..nut not very tight ( bit of oil behind prop yoke not reached outside yet ) so sealed that at same time

8th Dec 2013 9:04pm

ickle

Member Since: 22 Jul 2010
Location: South Vendee
Posts: 1790

2008 Defender 110 Puma 2.4 CSW Alpine White

Hi Munch,

going back to your earlier idea and Pete's picture on an earlier thread, would the notch in the casing allow a spray grease applicator access to the splined portion? (are they approx in line?)

Cheers Keith

8th Dec 2013 9:19pm

munch90

Member Since: 26 Oct 2013
Location: guildford
Posts: 3558

I drilled a bigger hole in line with joint inside then put camera in to check and could see bit of brown dust on screen so took the box out .. There is a seal in between shaft and cup but maybe if you kept spraying with a thin grease some may get in to joint .. The little drain hole ( small oblong one at end of casing ) is no where near inline with bit that needs greasing

8th Dec 2013 9:28pm

Supacat

Member Since: 16 Oct 2012
Location: West Yorkshire
Posts: 11018

2013 Defender 110 Puma 2.2 XS DCPU Keswick Green

Anyone got photos to illustrate exactly which parts/where they are talking about?

12th Dec 2013 4:33pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17478

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

lrmaniac wrote:

Oficial, as in LR service bulletin? Or instructions to the dealer on how to do that "DIY" job? Can't we get a copy of that sheet?

The nearest oficial dealer here, never heard of such failure!

Official, as in if you buy new parts they are different to the originals.

28th Dec 2013 3:53pm

munch90

Member Since: 26 Oct 2013
Location: guildford
Posts: 3558

all they need is extra grease same as drive flanges on hubs if you pull the plastic cap off then get some grease into splines I have never had one worn at all .
just more work to do the transfer spline . but I would say mine is better since greasing and if you do it before its worn its only labour and no parts to buy

28th Dec 2013 4:17pm

lrmaniac

Member Since: 04 Feb 2010
Location: Lisboa
Posts: 762

blackwolf wrote:
The internally-splined cup which attaches to the gearbox output spigot now has two diametrically-opposite grease nipples,

My mate that bought me the parts at LR did not bring any of that "new" part ! Same as the one before...

Can you by any chance get those new part numbers?

He did however fixed it and filled everything with grease when assembling...

I can tell you that I now have no strange sounds - clunks, bangs, whatever - coming from the gearbox (Only that anoying rattle)...much smoother and precise now! Regards
Joao

'10 Land Rover Defender 110 CC
'08 BMW F800GS
'64 SIIA Forward Control
'69 SIIA 109 ZA CKD
_____________________________________________
You have the right to remain silent. Anything you say will be misquoted, then used against you.

29th Dec 2013 2:11pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17478

When I get the chance (will be in the new year now) I will ask my source about this to try to find out more details.

29th Dec 2013 9:52pm

tazmarkuk

Member Since: 24 Jan 2012
Location: Birmingham
Posts: 134

Hi, this an old problem that all early Defenders suffered with, the issue was with the input gear, the replacement was a modified input gear with a cross drilled hole to help with lubrication. All new TD5's TDCI onwards would have been fitted with this gear even if you had a replacement box fitted it would have come fitted. To check you have this gear on the back of the transfer box is a circular disc, the PTO cover, remove this and you can remove the input gear and check if it's the crossed drilled type. Another modification was to weld a piece of tube cut in half to so you have a half moon shaped piece of tube and weld to the inside centre of the PTO cover, this then acts as a drip feed to the input gear.

30th Dec 2013 11:16am

munch90

Member Since: 26 Oct 2013
Location: guildford
Posts: 3558

your talking about transfer end of shaft that problem was dealt with years ago with adapted gear as you say .. the problem here is other end of shaft where it joins to ford gearbox

its the adaptor shaft between ford box and rover transfer box .. different gearbox to tdi or td5

30th Dec 2013 11:26am

tazmarkuk

Member Since: 24 Jan 2012
Location: Birmingham
Posts: 134

Oh my apologises, but didn't they have the same symptoms of stripping the main shaft spline from the box as this is what will drive the input gear

30th Dec 2013 11:31am

munch90

Member Since: 26 Oct 2013
Location: guildford
Posts: 3558

yes it is same type of problem .. just different set up .. but greasing from factory would have helped in both set ups

30th Dec 2013 11:33am

natyeo

Member Since: 27 Jan 2013
Location: Bentham
Posts: 136

2014 Defender 90 Puma 2.2 HT Santorini Black

So to sort this its transfer box out? Mine lost all drive (17,000 miles) and is still under warranty, they took it back and sorted, just said it was a shaft and there was an up grade?????????
Now at 37,000 miles , just serviced and its clunking in low gears, where would these extra grease nipples be?
Any photos?// 2014 2.2 90 hard top , Warm M8000 , Scorpain winch bumper, Ashcroft rear atb
2012 2.2 tdci 110 Utility
1993 110 CSW Warn M8000 , Scorpain winch bumper , 2" lift , Roamerdive overdrive, on going
1971 Hybird 200tdi, 2 x truetracs,Extrem winch bumper, M8000, GKN overdrive & Coils 2" lift, Glynn Lewis cranked rear trail arms
1971 Series 3 88, Perkins 4203,M8000,SATs,O/D,

13th Jan 2014 8:49pm

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