 | Home > Puma (Tdci) > Tdci gearbox removal |
 
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| bga86 Member Since: 17 Jan 2014 Location: Here and there Posts: 205  
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Take the 4 torx screws out at the bottom of the gear lever and lift it out of the gearbox. As for leaving it as one and lifting it out, I hope your mates are very strong as it's a heavy lump! I prefer to split them as it makes things more manageable
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22nd Apr 2014 5:59am |
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| big steve Member Since: 24 Dec 2009 Location: hertfordshire Posts: 2456  
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I dropped my gearbox and transfer box out together with no issues on my own so you will be fine if there's a few of you
Steve 2015 2.2 tdci hardtop xs 3.2 conversion DONE 238bhp and 707nm torque and thats just the start ;-P hybrid turbo in build -done ready to fit ashcroft atb in transfer box 6 speed auto in build |
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22nd Apr 2014 6:37am |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17445 
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One advantage to splitting them (aside from the reductionin weight) is that it allows you to check the condition of the infamous splined joint on the gearbox output adaptor shaft. It is really a false economy not to check/lubricate/replace this when the box is coming out.
Agree also with the earlier comment about removing the gear lever housing. You may also want to fit the locating bushes (there's a TSB about these which sadly I cannot find at the moment) when reassembling since they are pennies and improve the gearchange significantly. |
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22nd Apr 2014 10:35am |
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| MK Member Since: 28 Aug 2008 Location: Santiago Posts: 2420  
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such splined joint is that protruding from the extension or "inside" the gearbox extension? Puma 110" SW
............................................................. Earth first. Other planets later |
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22nd Apr 2014 1:36pm |
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| MartinK Member Since: 02 Mar 2011 Location: Silverdale (Lancashire/Cumbria Border) Posts: 2665 
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 This one I guess: http://www.defender2.net/forum/topic24561.html Defender "Puma" 2.4 110 County Utility (possibly the last of the 2.4's) |
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22nd Apr 2014 1:49pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17445
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The splines which fail are those inside the extension housing, not those which protrude into the transfer box.
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22nd Apr 2014 4:37pm |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17445
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That's the one, thanks! |
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22nd Apr 2014 4:40pm |
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| Shepherd Member Since: 21 Apr 2014 Location: Devon Posts: 22 
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Evening,
Thanks for the replys and advise. I removed the gear stick and have dropped the gearbox and transfer as one lump. Will do some research now on the splines as that's new to me. Might split in on the floor and lift it back in in two. It not the first clutch as it was dated 2010. I had a bad rattle when warm and a horrible notchy change in lower gears. The springs in the old clutch are very loose and the clutch rattles well when shaken. I have a an AP replacement with latest part number (different to one I just removed) however 2 of the spring are still just a tiny bit loose, is this normal? Will pick up a new slave cylinder tomorrow and get it put back together |
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22nd Apr 2014 7:04pm |
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| Phoenix90 Member Since: 04 Mar 2012 Location: Cornwall Posts: 377 
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To get you started: http://www.defender2.net/forum/topic21391....sfer+shaft http://www.defender2.net/forum/topic11955.html There was some talk on here a little while ago suggesting that Ashcrofts were engineering an upgraded part to replace this one. I've not heard anything since and there is nothing on their website, but may be worth giving them a call just to check if you decide to replace it. |
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22nd Apr 2014 7:56pm |
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| Shepherd Member Since: 21 Apr 2014 Location: Devon Posts: 22
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 Click image to enlarge Click image to enlarge Hopefully above should be pics of shaft. The fine splines are quit worn so going to replace this and the collar as I'm in this far. |
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23rd Apr 2014 8:46am |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17445
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What mileage has that shaft done?
It is well worth doing in my opinion, since the parts are not especially expensive (c. £120 IIRC) but it is a pain to drop the t-box to get at. Also if/when it fails on the road you are totally without drive (so sod's law says it'll fail halfway across a juntion, or in lane 3 of the motorway)! Was there any lubricant on the splines when you took it apart? The worst year for failures (based on an irresponsibly small sample admittedly) seems to be 2010, when many vehicles left the factory with completely dry splines. Don't forget to lubricate the splines when you put it back together. Thaks for posting the pictures, by the way. Intersting to see. |
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23rd Apr 2014 9:19am |
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| Shepherd Member Since: 21 Apr 2014 Location: Devon Posts: 22
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Thanks for the advise blackwolf, I'm glad I'm doing it now while it on the bench.
It's was all very dry when I pulled it apart. The new shaft was 43 quid and 53quid for the coupling so not too bad. Would you lube with grease or copper slip when I put it back together? |
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23rd Apr 2014 10:54am |
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| blackwolf Member Since: 03 Nov 2009 Location: South West England Posts: 17445
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Landrover doesn't recommend a lubricant for this joint since Landrover doesn't reckon it needs to be lubricated!
I have been researching this question with a view to doing mine, and the area with the most expertise of lubing splines seems to be the shaft-driven motorcycle fraternity. The almost universal recommendation there is a product made by Honda called "Moly 60", since it is 60% molybdenum (molybdenum is reckoned to be the best lubricant for metal-to-metal sliding surfaces). So when I come to do mine, I intend to pop into my local Honda motorcycle dealer to try to get some. If the Honda stuff proves unobtainable, then the second choice in my book is the trad Castrol Moly Grease (what used to be called Castrol MS3 if I recall correctly). This is actually a lithium based grease with a certain amount of molybdenum added, albeit nothing like the 60% in the Honda product. It is however widely available and generally inexpensive. Bottom line is that any lubircant is going to be better than the none that was there before. |
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23rd Apr 2014 3:29pm |
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| bga86 Member Since: 17 Jan 2014 Location: Here and there Posts: 205
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First time I've seen a shaft outside of the box, do they just pull out? What are the part numbers of the repair bits shepherd? May aswell change mine when it has a clutch I think!!!
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23rd Apr 2014 7:28pm |
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