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jamesthebaker



Member Since: 17 Oct 2022
Location: Brittany
Posts: 32
France 2004 Defender 110 Td5 SW Alaska White
Removing steering shaft on TD5
Hi everyone, it's me again,

I'm trying to remove my steering box to change the gaskets as it's leaking. To start with I have been trying for one week to remove the steering shaft without success. I have the following model :





I'm trying to remove the torx screws but the thread must be rusty as I can't remove them. For one week I have added WD-40 twice a day to hope for change but it did not improve anything. I also tried to heat the top screw with a torch but I was afraid to damage the servo brake above so I did not heat too much and it did not help.

I'm adding picture of my actual shaft if that can help :



Click image to enlarge


Click image to enlarge



Click image to enlarge



Click image to enlarge


What do you think is my best way to remove the shaft ? Do you have any tips ?

I must have the steering box fixed by the 20th December, so any advice that can make the process quicker are more than welcome Smile

Thanks again !
Post #972560 27th Nov 2022 10:52am
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ibexman



Member Since: 13 Dec 2008
Location: Essex
Posts: 2945
United Kingdom 
Have you removed the steering box
Post #972561 27th Nov 2022 10:57am
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jamesthebaker



Member Since: 17 Oct 2022
Location: Brittany
Posts: 32
France 2004 Defender 110 Td5 SW Alaska White
No because I would need to uncouple the shaft to the steering box first Sad
Post #972562 27th Nov 2022 11:00am
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Tr90



Member Since: 06 Jan 2020
Location: Essex
Posts: 135
United Kingdom 2000 Defender 90 Td5 CSW Alveston Red
Hi.

I have just replaced my steering box on my 2000 td5. It looks like I have a slightly different shaft to you.

However. I didn't take the shaft off. I undid the pinch bolts holding the shaft on to the splines of the upper steering column and the shaft from the steering box. Not the ones holding the UJ to the shaft.

After applying a little lubricant I found that I could tap the shaft upwards and it came free of the steering box.

To be fair the removal and refitting of the box was harder than I thought due to the weight of it and trying to line everything up.

TOP TIP - mark the shaft and the steering box spline so you will know where to rejoin once its is back in place.

I found this video very helpful -https://www.youtube.com/watch?v=S0JC5ZdU8U0
Post #972564 27th Nov 2022 11:11am
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jamesthebaker



Member Since: 17 Oct 2022
Location: Brittany
Posts: 32
France 2004 Defender 110 Td5 SW Alaska White
Thanks for your answer Smile

I'm trying to follow the video you sent, which is very good Smile

Unfortunately I'm not able to remove a single bolt holding the shaft to the splines. I guess they're rusty and I have no clue of how to remove them as lubricant and little heating don't help.
Post #972566 27th Nov 2022 11:25am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17363
United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
You have no alternative, you have to be able to loosen at least two of the (male) Torx head screws. There is no other was to remove the steering shaft or box.

Even if you were to cut the shaft to remove the box, you'd still have to remove the remains.
Post #972568 27th Nov 2022 11:37am
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jamesthebaker



Member Since: 17 Oct 2022
Location: Brittany
Posts: 32
France 2004 Defender 110 Td5 SW Alaska White
Yes that's what I was afraid of.

Any tips that I may not have thought of to manage to unscrew these bolts ?
Post #972569 27th Nov 2022 11:39am
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jamesthebaker



Member Since: 17 Oct 2022
Location: Brittany
Posts: 32
France 2004 Defender 110 Td5 SW Alaska White
Other question, do you think the servo brake can handle a lot of heat ? Can I keep on trying to use the torch below it ?
Post #972571 27th Nov 2022 11:45am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17363
United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Make sure that you are using the correct socket or wrench and use the longest handle you can. You may be able, by positioning the steering carefully, to use an impact wrench. I'd be wary of heat due to the proximity of the servo, steering box, and other heat-sensitive components.
Post #972589 27th Nov 2022 1:39pm
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Tr90



Member Since: 06 Jan 2020
Location: Essex
Posts: 135
United Kingdom 2000 Defender 90 Td5 CSW Alveston Red
Plenty of lubricant and the right size socket and extension bar. Wouldn’t use heat. Impact wrench is a good call.

Just a heads up. You really should get some assistance fitting the steering box back in place. It is not easy holding it up with one hand and trying to fit the bolts back.
Post #972591 27th Nov 2022 1:53pm
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Dinnu



Member Since: 24 Dec 2019
Location: Lija
Posts: 3414
Malta 2012 Defender 90 Puma 2.2 CSW Santorini Black
As suggested above, and if you manage to rotate it slightly, do not keep undoing, but rotate back and forth and undo a little bit more and repeat with the back and forth motion. This lets the lubricant in and the rust out of the threads.

Also ensure that the protruding threads are clean, but I think they are according to one of the pics. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing
2012 90 CSW, 2.2TDCI, Santorini Black
Post #972594 27th Nov 2022 2:12pm
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ickle



Member Since: 22 Jul 2010
Location: South Vendee
Posts: 1777
France 2008 Defender 110 Puma 2.4 CSW Alpine White
Once the bolts are loosened, if I remember correctly, the flat section of the shaft doesn't continue to the end, so it is necessary to take the bolts out completely to remove the shaft - I also loosened each side of each of the UJ's as it gave a little more travel to move the shaft away.

HTH Keith
Post #972596 27th Nov 2022 2:44pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17363
United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
^^ Indeed, and this makes it a complete pain if one of the bolts shears off!
Post #972598 27th Nov 2022 3:08pm
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Balvaig



Member Since: 19 Feb 2016
Location: Fife
Posts: 730
Scotland 2016 Defender 90 Puma 2.2 Landmark LE Corris Grey
WD 40 is not a penetrating oil, just a water dispersant. A proper penetrating oil/ lubricant should help.
Good luck, sounds like a b of a job.
Post #972600 27th Nov 2022 3:22pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17363
United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
If you don't have any proper penetrating oil (such as Plus-Gas) use diesel fuel, it's surprisingly effective and much better than WD40 as a penetrant.
Post #972603 27th Nov 2022 3:57pm
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