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Fifth Horseman



Member Since: 08 Mar 2011
Location: Lanarkshire
Posts: 322

United Kingdom 2011 Defender 110 Puma 2.4 XS CSW Santorini Black
Another gearbox adaptor shaft bites the dust
Thread title says it all really, '60 plate with about 50K miles. Just collecting SWMBO from the railway station then bang & sound of stripped splines Sad

At least it happened next to a pub so I could cheer myself up with a few pints whilst waiting for the big yellow taxi.
Post #437125 11th Jul 2015 8:28pm
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ian series 1



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

United Kingdom 2008 Defender 90 Puma 2.4 CSW Bonatti Grey
Ahhh....don't you just love having this "time bomb" between the gearbox and transfer box Big Cry

Always knowing it's there, but never knowing when it's going to Censored up your day!


Hope you get it sorted soon. Mad 80" 80" 86" 88" 90"

Wanted, Forward Control Anything considered.
Post #437126 11th Jul 2015 8:37pm
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Fifth Horseman



Member Since: 08 Mar 2011
Location: Lanarkshire
Posts: 322

United Kingdom 2011 Defender 110 Puma 2.4 XS CSW Santorini Black
I would certainly like to get hold of the knob who decided that the splines on that shaft didn't need greasing on assembly Evil or Very Mad

It will have to wait till Monday so I can phone around some places.

Anyone know how heavy the LT230 transfer box is - just wondering about the ease of doing it on the drive.
Post #437127 11th Jul 2015 8:44pm
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Rickydodah



Member Since: 14 Jul 2014
Location: East Sussex
Posts: 1091

Transfer Box is easy enough to remove albeit heavy. Easily enough though with two, I wouldn't attempt it on your own, extension housing isn't a problem either. The shaft is held in by a circlip. But on mine the coupling was a right bar steward to get off. Had it come off easily then it's a good morning's work. Thumbs Up I started with nothing and still have most of it left!

Last edited by Rickydodah on 11th Jul 2015 9:02pm. Edited 1 time in total
Post #437130 11th Jul 2015 8:59pm
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Roy5695



Member Since: 15 Feb 2014
Location: Cornwall
Posts: 1123

United Kingdom 2011 Defender 110 Puma 2.2 XS DCPU Indus Silver
It would be worth fitting a modified adaptor, this allows oil to lunricate the shaft and prevents this problem from happening again. The name of the company escapes me now, a very well known company though, especially for gearboxes.
Post #437131 11th Jul 2015 9:00pm
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Fifth Horseman



Member Since: 08 Mar 2011
Location: Lanarkshire
Posts: 322

United Kingdom 2011 Defender 110 Puma 2.4 XS CSW Santorini Black
Ashcroft is the company you are thinking of. TBH I'm not completely convinced that their solution is optimal, although the cover that is part of the kit will certainly stop the shaft moving backwards as has happened on some of the failures that have been seen.
Post #437133 11th Jul 2015 9:03pm
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munch90



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

England 
What i dont get about the reports of the shaft moving out of the spline is the plastic cap that fits over is held by a cable tie and the cap has tags on the end that fit over the back of the outer splined cup , no one i far as i know has said there cap was broken , so how has spline moved ?

also the oil seal in the transfer box polishes a ring on the adaptor seal , only ever seen 1 ring for the shaft to of moved there would be 2 polished rings

also the area on the adaptor shaft is quite short where the seal rubs , if it moved wouldnt it then damage the seal as the rest of the shaft isnt machined to have a seal run on it
Post #437153 11th Jul 2015 10:12pm
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20284

United Kingdom 
Fifth Horseman wrote:
Anyone know how heavy the LT230 transfer box is - just wondering about the ease of doing it on the drive.

About 70 - 80kg and not that well balanced either to handle, easy enough to crush you!
Post #437159 11th Jul 2015 10:26pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17321

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
The transfer box is very easy to remove with the aid of a transmission jack if you're working solo on your drive. To remove the coupling, the special tool (to hold the 'socket' attached to the main gearbox) is a real bonus. You are also likely to need a slide hammer (to get the shaft out of the socket) and a decent puller (get the socket off the gearbox).
Post #437181 12th Jul 2015 6:37am
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Fifth Horseman



Member Since: 08 Mar 2011
Location: Lanarkshire
Posts: 322

United Kingdom 2011 Defender 110 Puma 2.4 XS CSW Santorini Black
Due to lack of time (and a transmission jack) it will probably be going to a local indie to be sorted. I'm now planning to get the clutch replaced at the same time as its starting to chatter with the gearbox in neutral.

Could have been worse - like half way up the A1 with the tin tent in tow.
Post #437182 12th Jul 2015 6:52am
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Nevillerover



Member Since: 14 Feb 2015
Location: Suffolk
Posts: 224

United Kingdom 2007 Defender 110 Puma 2.4 XS CSW Sumatra Black
Mr Horseman, I also live in Suffolk. Where are you planning to have this job done and do you know the likely cost please? I too have a chatter in neutral for a couple of minutes when cold and I'm also thinking that a new shaft would take out a bit of slack so it's something I will consider having done.
Post #437185 12th Jul 2015 8:04am
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Fifth Horseman



Member Since: 08 Mar 2011
Location: Lanarkshire
Posts: 322

United Kingdom 2011 Defender 110 Puma 2.4 XS CSW Santorini Black
The chatter in neutral is unrelated to the adaptor shaft - its due to the springs in the clutch wearing, eventually it will sound as though there is a bag of spanners being shaken under the vehicle. If its only a light chatter I wouldn't worry about it yet.
If the adaptor shaft splines are worn it will introduce some slack in the transmission. The greatest problem is there is very little warning before they let go (I managed about 3 miles).
Not sure which garage I will use yet although will probably be one near Cambridge (very unlikely to be Marshalls due to their eye watering about rates).
Post #437186 12th Jul 2015 8:26am
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CFB



Member Since: 13 Sep 2007
Location: Bradford, West Yorkshire
Posts: 803

United Kingdom 
Anyone paid for a dealer to do this work and if so what's the cost pls? Andy
Post #437189 12th Jul 2015 8:34am
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mk1collector



Member Since: 17 Sep 2009
Location: West Yorkshire
Posts: 6769

England 2004 Defender 110 Td5 CSW Bonatti Grey
It might be worth taking it too a dealer as the Landrover rep on here said that the coupling should be greased from factory so Landrover should (in theory) foot the bill if no grease!
http://www.defender2.net/forum/topic36916.html
Page 5 on this thread, the post by Ryan the Landrover rep. Ray
My build thread
http://www.defender2.net/forum/topic17615.html
Post #437205 12th Jul 2015 9:50am
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munch90



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

England 
don't think any were greased from the factory

think the greasing was part of the tech bulletin on replacement of the shaft
Post #437210 12th Jul 2015 10:18am
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