 | Home > My Defender > The german big black 110 |
 
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| Dinnu Member Since: 24 Dec 2019 Location: Lija Posts: 3513   
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Unfortunately the transfer boxes on Pumas do not seem to last as long as they did on the predecessors.
There could be several reasons to why. The Puma has very high cyclic loads, and perhaps made worse by the thicker, hence stiffer half shafts. The oil leak from the front (if by front you mean the face where it mates with the gearbox adaptor housing) is generally caused by the intermediate shaft O ring that looses its ability to seal as it sets to a squarish profile over time. However there is also a possibility that the hole for the intermediate shaft in the aluminium casing to go oval and a new O ring would not solve the leak. But there are also upgrades for that - just google "LT230 sleeve casing" either by getting a modified casing, or getting just the sleeve and modifying your case and installing locally. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing 2012 90 CSW, 2.2TDCI, Santorini Black |
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30th Jul 2022 7:08am |
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| Honeyman Member Since: 02 May 2022 Location: Haarlemmermeer Posts: 58  
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If it’s any consolation, this is what the drain plug on mine looked like yesterday….
 Click image to enlarge 2011MY 130 HCPU: daily driver 1979MY RRC 2-door: on the drive, in the garage & in a shed - all at the same time. |
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30th Jul 2022 10:39am |
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| roamfree Member Since: 19 Jan 2022 Location: Northern Germany Posts: 24  
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My condolences honey man, that looks bad indeed! Guess I was lucky after all 😆
Hope yours will be fine! |
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1st Aug 2022 4:34pm |
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| Honeyman Member Since: 02 May 2022 Location: Haarlemmermeer Posts: 58
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Thanks! It will be fine eventually - made a start at least
Click image to enlarge 2011MY 130 HCPU: daily driver 1979MY RRC 2-door: on the drive, in the garage & in a shed - all at the same time. |
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1st Aug 2022 5:50pm |
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| Caterham Member Since: 06 Nov 2008 Location: Birmingham Posts: 6324  
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/\ I think its possible for these things to be fine eventually, after much, time, effort and money.
Assuming of course you set the bar very low as to what fine is  |
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1st Aug 2022 7:37pm |
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| roamfree Member Since: 19 Jan 2022 Location: Northern Germany Posts: 24
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It's been a while! Just as with every Defender there have been countless ups and downs this past one and a half years. All in all I am quite happy with the big black, but there are of course the next problems looming on the horizon. But before we get into the nitty gritty let's enjoy the more pleasurable experiences of 2023:
It starts with travel preparations in May: Click image to enlarge U-Joints in the front were due While it was up on the lift, I noticed that it was leaking from the transfer case... Click image to enlarge Defender on the lift So the front output flange and corresponding seal was changed... Click image to enlarge New front output flange of the transfer case ... that helped a ton, but still the transfer case is not 100% dry. A bigger journey was upcoming so fluids were in order: Click image to enlarge changing the front diff oil, and violating the new diff guard in the process Since we wanted to drive in convoy, a radio was needed. But where to place the antenna? I didn't want to do any drilling... so a custom mount was to be fabricated: Click image to enlarge custom antenna mount in the making Click image to enlarge finaly product and freshly mounted antenna And on the journey went: Click image to enlarge western alps 1 Click image to enlarge western alps 2 Click image to enlarge Denmark Click image to enlarge Norway And of course it wouldn't be a defender without a water leak, what a way to start 2024! Click image to enlarge leak 1 But I don't think it was this clean since August, so thats something I guess 
Click image to enlarge leak 2 Currently dismounted the rack since I have some corrosion on the alpines and was thinking of tackling it. But I might wait till summer honestly... Click image to enlarge a clean Defender in the city I gotta say though, I kind of love the clean aesthetic of the defender without the roof rack. |
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19th Feb 2024 10:08pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10940
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Thank you for your update and the pics on " big black " great your still enjoying defender life and it wouldn't be the same if you were not tinkering on it
Hope you get the water leaks sorted this year  Clayton.
1996 Golf Blue 300Tdi 110 Pick up. Keeper. |
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19th Feb 2024 10:26pm |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20702 
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Looks good! first time I’ve seen your thread, there is always something to do with a Defender, the works never ends.
TheThunderRolls🇬🇧🇺🇸
⛽️🛢️⚙️🧰💪 |
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20th Feb 2024 12:05am |
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| Waka56 Member Since: 08 Nov 2023 Location: Hamburg Posts: 170
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Nice big black! Got a big white recently, which needs a fair bit of work. Might see you around in Hamburg
 Making my Defender great again. (Or trying to at least xD) |
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21st Mar 2024 7:41pm |
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| roamfree Member Since: 19 Jan 2022 Location: Northern Germany Posts: 24
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Thanks folks!
The water leak indeed seems to be sorted for now @L11CDL. Lets pray that it stays that way, Hamburg is showing itself in its greatest glory again at the moment. However I seem to have some corrosion on the alpines which will need fixing... and thereby possibly needing to respray the whole roof. Guess there's always something, just as you said @custom90! Speaking of things that need fixing: Three weeks ago the ignition switch decided to die, so that needed sorting: Click image to enlarge With the steering wheel off I decided to finally mount that christmas gift and get rid of that ugly Raid logo: Click image to enlarge Click image to enlarge The wire-loom for the rear passenger doors was broken and thus my central locking was done for. So that was the next job that I tackled. Click image to enlarge Unsure about the alpines, but besides those I really hope that this is it with major suprises this year. I would love to spend the money on some fine new upgrades instead of repairs for a change
@Waka I'll keep my eyes open! Always happy to connect to other Defender drivers |
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28th Mar 2024 6:16pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10940
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Nice bit of maintenance work your carrying out on the 110
You have to be patient with finding the money to spend on upgrades, that time will come one day for you  Clayton.
1996 Golf Blue 300Tdi 110 Pick up. Keeper. |
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28th Mar 2024 10:23pm |
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| roamfree Member Since: 19 Jan 2022 Location: Northern Germany Posts: 24
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I cannot believe it's been already a year since an update here. It's about time! And what better occasion could there be than a little (big) maintenance.
Soooo let's start with a little recap of the last year. After the water leak beginning of 2024 it was found that the leak was from the windscreen seal, so the windscreen was replaced. Conveniently the car was in the workshop already, because the starter decided to die on me a few days earlier. In September service was due. I had noticed that there was a lot of black smoke coming from the exhaust, so it was investigated. Turned out a seal in the turbo had blown and it needed replacing. Inspection at the garage furthermore showed that the rear brakes were toast by this point. So turbo and brakes were due. Since the car was at the indie anyway, I was dumb enough to let them tackle those... I sure regretted not doing it myself after receiving the bill. Now as if that was not already enough, the transfer case started leaking from the intermediate shaft and by now I could hear the springs in my clutch plates rattle. After the last visit still left me grinding my teeth, I was to make a decision. Do it myself or spent another fortune that I did not really posses. One could say 2024 was a rather turbolent year, even though I did not drive all that much sadly. I wanted to change that and take the Defender finally overlanding again this year. Soooo, transfer case and clutch needed tackling! After pleading with friends, they were kind enough to repark their own Defender and make space in their garage for me. This is the first major operation I was about to conquer, having no engineering experience under my belt what so ever. I am an IT guy after all. So this was quite daunting to me... However, before I could start with the tc and clutch, one more obstacle decided to pop up. See, my MOT was due this January. Shortly before Christmas I got a call that a MOT appointment became free and if I didn't want to take it. I knew of the leaking transfer case, but thought nothing a little brake cleaner before the inspection couldn't fix. So in I went. Weeeell, as it turned out the big one was not burning all its Diesel, leading to nearly failing the emission test. By sheer luck I came through, but I knew something was afoot. After some research, I came to the conclusion that at 120k kilometers, it was possibly the injectors on their way out. So, those needed tackling as well. What a job to start into the year to! And thus, I booked myself in at my friends for most of January. Click image to enlarge The operation is about to start! First up? injectors) Click image to enlarge labeling everything up Click image to enlarge Injectors sure not looking to good anymore after 120k Click image to enlarge rockers not looking to shabby Click image to enlarge camshaft and roller on the other hand not locking to good there... Do you folks think this needs addressing? Click image to enlarge all new injectors going in Click image to enlarge a quick test drive revealed some problem with cylinder 4. That'll need sorting soon enough... Click image to enlarge checking for leaks using some baby powder Sooo turns out the leak from the injector was not the injector at all, but the fuel line. I got lucky there driving round with a leaky line. After changing the line is was problem solved! VCV Since I was dealing with some kind of fueling issue and the Defender was idling quite roughly as well as smoking too long after acceleration, I thought replacing the VCV might be a good thing to do. Universe had other plans though... Click image to enlarge Previous owner already changed the vcv at least once. The right bolt was so tight that I stripped the screw... Since I have not dared touching it again for fear of ending up having to remove the whole bloody pump in the end... intermediate shaft) Because the transfer was coming out in any case, I finally had the opportunity to fit the LOF MT82 Extreme Output shaft that I was driving around for coming up on year at this point. Click image to enlarge Click image to enlarge This thing was beyond rusty, so good I changed it and now have peace of mind. Click image to enlarge LOF output shaft in all its machined glory.Take up is much much smoother now after the change. new clutch) Click image to enlarge turned out the previous owner put a transit 4x4 clutch in Click image to enlarge sadly the previous workshop must have put the accessible bolts down at the button in with an impact gun. Threads were stripped and one screw broke in the process of removing the gearbox Click image to enlarge Luke's sticker saving my day... previous indie workshop was just as unaware as me of there being different spec flywheels around. Back then I trusted their judgement that the clutch was still fine and had it reassembled after a slave cylinder failure... That was about 50km after I had acquired the car 
Click image to enlarge new powerspec clutch in after sorting out a new clutch cover with Luke. Click image to enlarge I had hoped of getting away with not removing the starter (it was stuck), but damaged the seal when reassembling 
Click image to enlarge Sooo I had to get creative and reglue it in situ Click image to enlarge Final step: relocating the clutch hose bracket. Shoutout to @ickle (Keith) and @custom90 for bearing with my stupid questions! transfer case) Click image to enlarge not so nice finding after having the tc removed. The center diff seems on its way out... Click image to enlarge big chunks of copper in the input housing, likely coming from the thrust washer in the center diff. Click image to enlarge the gears itself still look good Click image to enlarge new intermediate shaft and o-rings going in Click image to enlarge ...and because I couldn't leave the box this time around some silicone... Click image to enlarge Having been on my list for ages, a high cap sump went onto the tc when it was reassembled. Not what I had hoped for. Since I do not have the money to have it rebuild and I do not trust myself with rebuilding it myself, for now I'll have to live with it. Guess an ATB will need to replace the by then probably worn center diff when I can afford having the box rebuild. Let's hope soon 
so where do we stand? Well, I have not been able to get the gear selection to be quite as perfect as I would have hoped, but it still is a world of a difference with the new clutch and the intermediate shafts. Shifts are crisp and I do have to be way less careful in order not to produce the typical backlash in the drive line. Makes for way more comfortable driving 
Nooow however, the next problem looms on the horizon. Now already for the third time, my ABS and TC lights stayed on and the nanocom reports a "shuttle valve switch failure (13-07)". With me not being much of a electronics guy, I fear the next trip to the indie is on the horizon... but for the moment being, I will allow myself to be proud of the operation undergone succussfully
Thank you again for everyone in this forum that enables even noobies like me to work on these beautiful cars. I would not have dared without all the great guides, tips and the sheer amount of knowledge collected here. Cheers folks! |
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11th Mar 2025 9:06pm |
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