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RichardBattersby

Member Since: 07 Aug 2013
Location: North Yorkshire
Posts: 57

2015 Defender 90 Puma 2.2 HT Corris Grey

Door Sill / Battery Box Corrosion

Hi,

I've noticed some corrosion at the corner of the seat box so I bought some YRM stainless sills to go in.

However, on closer inspection, I've noticed that on the passenger side there's an extra sheet of metal between the box side and the sill, it's this that's heavily corroded. See below:

Click image to enlarge

Click image to enlarge

This is what the drivers side looks like:

Click image to enlarge

Click image to enlarge

I obviously want to remove that piece of metal but as you can see, I've removed the bolts and it won't budge. How do I get it out?? Why is it just on one side? It looks like the factory were trying to fill the gap and I haven't found any pics on here or online that show this extra piece. Defender 90 HT Corris Grey Puma 2.2TDCi

16th Nov 2020 12:38pm

LandRoverAnorak

Member Since: 17 Jul 2011
Location: Surrey
Posts: 11324

I think that's the pressing for the bottom of the battery box and it's a different arrangement on the drivers side. I'm pretty sure that the only way to remove it would be to take out the entire seat box. Darren

110 USW BUILD THREAD - EXPEDITION TRAILER - 200tdi 90 BUILD THREAD - SANKEY TRAILER - IG@landroveranorak

"You came in that thing? You're braver than I thought!" - Princess Leia

16th Nov 2020 1:13pm

lakelander

Member Since: 07 Jan 2017
Location: Cumbria
Posts: 100

2013 Defender 90 Puma 2.2 CSW Orkney Grey

I had the same problem, it looked a right mess and the seat boxes edged were beginning to crumble.So I also fitted the YRM threshes. The problem is caused by electrolysis between the aluminium panels and steel bolts pieces. When I put it together again I fitted a gasket between them ( cut up an old head gasket )and used Duralec paste as I put in the YRM stainless bolts.
Don't remember the two sides being different?
Mine is a 2013 model with unpainted sills _ thought the newer models had colour matched sills ?

16th Nov 2020 2:21pm

L90Andy

Member Since: 29 May 2014
Location: Stratford-Upon-Avon
Posts: 719

Yep, the crusty bit shown in the picture on the passenger side is the battery box base which is sandwiched between the seatbox and the sill.
I recently replaced the battery box on my old '84 Ninety but did so with the seatbox still in. This was only possible as I cut the battery box into pieces in-situ before it dropped out the bottom. The replacement was a YRM ally version that I assembled in-situ too. Depends how much of a stripdown you want to do to resolve it. Instagram: L90andy

My 1984 Ninety: http://www.defender2.net/forum/topic56071.html - SOLD!
My 2015 Defender: http://www.defender2.net/forum/topic39625.html - SOLD!

16th Nov 2020 3:41pm

Greeny

Member Since: 20 Mar 2018
Location: Buckinghamshire
Posts: 272

Recently replaced both seat ends on my TD5. Did a write up on the thread below.

https://www.defender2.net/forum/topic72237.html

Not sure about replacing the battery box and whether that can be done in situ or not. But by removing the seat box end everything is a lot more accessible to repair/replace.

Before and after pictures below of the seat box end replacement.

Click image to enlarge

Click image to enlarge Instagram - @Land_Rover_Defender

16th Nov 2020 4:15pm

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