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excossack

Member Since: 22 Feb 2012
Location: North West
Posts: 5851

1999 Defender 110 Td5 SW Caledonian Blue

Transfer case - stripped threads - drain plug

The threads on the drain plug hole (transfer case side) have stripped.
I had a couple of thoughts on how to fix;

Drill and tap and replace drain plug with a slightly bigger size
Epoxy and bond the drain plug in place.
Buy a new TC from Ashcrofts with some upgrades.
Scream

So far I have managed to get the drain plug in and stay in, but not sure how long this will hold. A combo of copper washer and rubber washer to try.

I did consider removing the inspection cover and getting from the other side and replacing with a nut and bolt but I don't think there will be enough room but will have a look at the old transfer case in the shed and see what there is. The old one was considered, but needs new bearing on the front output shaft, rear output shaft leaks and jumps out of low box.

Bummer

1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock

22nd Jun 2018 9:34am

rallysteve

Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2237

2002 Defender 110 Td5 DCPU Keswick Green

John,

Halfords do these repair ones which might be a possibility?
http://www.halfords.com/motoring/car-parts...lug-hfx693

Not sure if there is enough room for the wings to fold out though. They do a couple of sizes i think.

Steve 02' 110 TD5 Double Cab Rebuild Thread

22nd Jun 2018 9:44am

MartinK

Member Since: 02 Mar 2011
Location: Silverdale (Lancashire/Cumbria Border)
Posts: 2665

2011 Defender 110 Puma 2.4 USW Orkney Grey

^^ that's a great find rallysteve

Defender "Puma" 2.4 110 County Utility (possibly the last of the 2.4's)

22nd Jun 2018 10:34am

jst

Member Since: 14 Jan 2008
Location: Taunton
Posts: 8051

2011 Defender 110 Puma 2.4 USW Stornoway Grey

Recap to larger size Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop

22nd Jun 2018 12:15pm

excossack

Member Since: 22 Feb 2012
Location: North West
Posts: 5851

That was a good find Steve, but on opening the spare transfer case there is not a lot of room between the drain and a big gear.

Drain plug seen poking out the side of the case

Click image to enlarge

@JSt - Racap/rethread might have to be the order of the day 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock

22nd Jun 2018 5:38pm

Pilgrimmick

Member Since: 16 Nov 2015
Location: Highlands
Posts: 582

Helicoil! 80" 1948
Lightweight V8
Bowler Tomcat
130 Station wagon
90 300tdi
(Santana PS10 pick up)
Range Rover L322 (Ful fat)

22nd Jun 2018 6:15pm

excossack

Member Since: 22 Feb 2012
Location: North West
Posts: 5851

That might be the answer.. Not sure how you use them but maybe the answer. 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock

22nd Jun 2018 8:14pm

williamthedog

Member Since: 29 Dec 2012
Location: south wales
Posts: 3441

Go for a time sert, stronger and longer lasting than a helicoil 👍

22nd Jun 2018 8:18pm

excossack

Member Since: 22 Feb 2012
Location: North West
Posts: 5851

Do these screw in, hammer in, drill in ? I assume once in, then you insert the drain plug(or replacement)? 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock

22nd Jun 2018 8:37pm

williamthedog

Member Since: 29 Dec 2012
Location: south wales
Posts: 3441

Ok, it's probably best if you take it to a trustworthy garage, they shouldn't charge you that much. It saves you from the initial cost of the inserts and fitting kit

22nd Jun 2018 8:56pm

excossack

Member Since: 22 Feb 2012
Location: North West
Posts: 5851

I think that is my next move. My normal garage have a good bunch of lads. They get all sorts, classic e type, stags, etc right up-to modern day motor cars and my 110

1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock

22nd Jun 2018 9:40pm

excossack

Member Since: 22 Feb 2012
Location: North West
Posts: 5851

Since I did the temporary fix the car has been fine. Discovered today a ring of oil on the floor under the transfer case.

Car is booked in Monday to get fixed and at the weekend I have a rally!

1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock

26th Jun 2018 2:23pm

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