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blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17353

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Sealing it and fitting an oil slinger to the shaft would be an option, with maybe a couple of oil holes instead of nipples on the female part of the coupling. It would need a drain plug and filler/level plug in the housing.

Certainly another option.

29th Jan 2015 10:22am

munch90

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

a oil baffle plate would have to be fitted above the shaft as the top of the casing would be hard to seal as there is a big hole there for gear lever mech

sealing back and front of casing only needs silicone and the standard drain hole sealing then use something like ep140 oil or something that's not going to fling around and up to much

29th Jan 2015 10:40am

scotia

Member Since: 29 Oct 2014
Location: North Cambs
Posts: 96

2015 Defender 110 Puma 2.2 XS CSW Corris Grey

Does anyone know if the factory are now 100% making sure these splines are well lubricated prior to assembly?

29th Jan 2015 11:00am

ian series 1

Member Since: 17 Nov 2014
Location: south
Posts: 3127

2008 Defender 90 Puma 2.4 CSW Bonatti Grey

If they got away with it for this long I doubt they will bother now!! 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.

29th Jan 2015 12:35pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17353

scotia wrote:
Does anyone know if the factory are now 100% making sure these splines are well lubricated prior to assembly?

29th Jan 2015 12:41pm

flying_low

Member Since: 08 Apr 2011
Location: Masai Mara
Posts: 19

2011 Defender 110 Puma 2.4 SW Keswick Green

Rear output shaft seal .... that's the one that leaks into the handbrake, and only requires removal of the handbrake and drive flange, right?

Are they complete morons?[/quote]

Yes! They are.
Now I have it in writing that JLR will not be able to "assist in this situation" because the while has not been inspected and serviced at a LR dealer. Due to this JLR is not in a position to utilise it's "goodwill budget" towards this issue.

So just because I'm remote and vehicle is serviced by me out in the bush -exactly were this vehicle was designed to work- and a lifetime part fails- they won't consider parting with £100..?!

I've still saved money and time on doing all the services myself and even the cost of these parts is still cheaper than having dealer work done... I'm still coming out on top here!

I have faith in the machine-just not in the people selling it!

Ok, rant over. On a serious note-
Have been looking at the shaft and coupling I've pulled out-there's a 'snap-ring' on the shaft that I supposed to 'lock' the front - splined end into the adaptor cup. Does anyone think it's possible that this ring could slip or somehow 'unlock' ??
This would presumably allow the shaft to slip backward-away from the adaptor coupling -as it were.

This is what it appeared like when I took the shaft and coupling out. Trying to fit them together, it was clear that the snap ring had taken damage from the shaft and cup not being locked together. Could it be tha the shaft was just never inserted properly in the first place? Or would that have led to a much earlier failure?
Alternatively- is it possible that rough roads (corrugation) and general dirt tracks might cause the shaft to vibrate out of place?

??? 2011 110 Tdci
1982 Range Rover V8 Classic (Gone)

2nd Feb 2015 9:29pm

miket

Member Since: 05 Oct 2012
Location: Peak District
Posts: 143

I've just had it confirmed that I've had my second intermediate shaft fail on my MY09 110. The garage have confirmed that it hadn't been greased when it was fitted 18 months (approx 18,000 miles) ago by another local indy garage (see the start of this thread). Since then I've not done any towing and very little in the way of off roading, so it's interesting to see how disappointingly short their life can be.

Rather annoying, but looking on the bright side i guess it could be worse. Suffice to say I've made sure that thie new shaft will be greased to within an inch of its life...

4th Feb 2015 4:32pm

Supacat

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

2013 Defender 110 Puma 2.2 XS 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.

I don't know how recent this is, so perhaps someone with a recent 2.2 could look underneath and see if their vehicle is so fitted. Also I don't know the part numbers involved, perhaps someone can advise?

Well mine's showing signs of wear and will be sorted under warranty - interested to know beforehand if there is modification or whether it's a like for like replacement and I may be going through the same thing again in another 10k miles!

2nd May 2015 3:11pm

munch90

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

think your find the modification is a bit of grease

2nd May 2015 3:21pm

Supacat

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

You may well be right, it would just be good to know either way. Following blackwolfs posting, I've not seen any reply from someone who has had it done confirming one way or the other. Should be simple to check if there's an extra hole in the casing now!

2nd May 2015 3:27pm

munch90

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

when I done mine to check for brown dust I drilled a hole in my casing and put camera in , could see very small amount of dust ,so took t/fer for a out proper look/check , all looked ok so just packed with cv grease and refitted

that was roughly year or so ago , just been under to check with camera removed bung I fitted , very small amount of grease spun out (probaley the grease that oozed out when fitting ) round inside casing and joint looks ok and greasy

2nd May 2015 3:51pm

ozrob

Member Since: 31 Dec 2013
Location: Snowy Mountains
Posts: 8

2013 Defender 110 Puma 2.2 SW Baltic Blue

Munch90
Are you able to supply a photo of where you drilled he hole to insert the inspection camera?
I have a MY13 110 with 66000km and have a big trip coming up at the end of the month...now I am worried.

3rd May 2015 10:42am

munch90

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

not got a pic but its about half way along the casing between t/fer and gearbox

all you can see is if there is brown dust inside the casing , you cant see the spline as its got a cover round it

of course only a small hole as you don't want to weaken the casing , mines a proper bore camera so only needs a very small hole

3rd May 2015 10:48am

ozrob

Member Since: 31 Dec 2013
Location: Snowy Mountains
Posts: 8

Thanks mate,
If I am going to drill a hole for the inspection camera, it might as well be a hole for a grease gun, so I would prefer to drill only one hole.

3rd May 2015 11:06am

ozrob

Member Since: 31 Dec 2013
Location: Snowy Mountains
Posts: 8

Now here is a thought,
If the extension housing is basically an empty space where the adapter shaft runs, the gearbox and T/Case is sealed,
Why cant the extension housing be filled with gear oil just above the adapter shaft to lubricate it?

3rd May 2015 11:12am

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