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Myo

Member Since: 13 May 2012
Location: Cape Town
Posts: 30

2010 Defender 90 Puma 2.4 CSW Stornoway Grey

So had all of the same symptoms myself! Took it to have the clutch kit installed under warranty, then 5000km later the clunk and drivetrain slack got worse and then she stopped altogether.
Turns out there's an intermediate shaft that connects the gearbox to the transfer box using male/female splines, these were worn out completely, mechanic told me he had never seen it before(but by the time I went to pick up the van a second defender had come in and had exactly the same problem), says its because the GB was not designed to have a transfer case so the intermediate shaft was the solution, I have some pics and will upload as soon as I figure out how.
Now much better, less clunk and much improvement in slack, though both still very much present, guess this is as good as its going to get.

22nd Nov 2012 1:51pm

Fifth Horseman

Member Since: 08 Mar 2011
Location: Lanarkshire
Posts: 326

2011 Defender 110 Puma 2.4 XS CSW Santorini Black

Myo
The same thing has been seen in the UK, at the bottom of http://www.defender2.net/forum/topic11955-75.html is the parts diagram of the affected area.
Seems like LR have been forgetting to lubricate some on assembly.

22nd Nov 2012 3:00pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17470

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Check both axles for backlash, worn halfshafts and drive members in the rear are common. On a 2008 Defender you probably have a two-pinion diff in the front, which will sooner or later fail. If there is mucho backlash in the front, drop the diff out to check.

If you sort out the drive train backlash you will find that the clutch and gearchange improves a lot.

When sorting the clutch (and you clearly need a new one) also renew the hydraulic flow restrictor. If this is blocked it will make it very difficult to change gear smoothly.

22nd Nov 2012 3:12pm

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