 | Home > Technical > PUMA MT82 stuck in gear - had a go at fixing nearly...help! |
 
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| landy andy Member Since: 15 Feb 2009 Location: Ware, Herts Posts: 5849  
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Have you accidentally knocked transfer box lever whilst fiddling??
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15th Mar 2025 7:02am |
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| custom90 Member Since: 21 Jan 2010 Location: South West, England. Posts: 20697 
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There is a possibility a spring has come out of the clutch friction plate, or the slave cylinder has sprung a leak, which is a concerning possibility.
In particular if the clutch is getting on a bit or high mileage, do you know how old it is? Is it a genuine LR clutch or another type do you happen to know? A loose spring that’s come out often give the impression of drive blocking in and out of gear, it seems like the clutch is active but the clutch plates can’t engage properly. That faint grinding is suspect, as would be the spigot bearing, if thrown of centre without concentric drive, I.e. if there is a spring blocking the plates. The LR Gen clutch has a habit of throwing a spring out with wear, well before the friction and drive plats have worn out. 
It’s possible the jolt did just that, possible as I mentioned. The new are less miles the clutch has done though, the less likely this is. Have you checked the clutch fluid level? Any signs of leaks or near the bleed valve on the trans? TheThunderRolls🇬🇧🇺🇸 ⛽️🛢️⚙️🧰💪 |
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15th Mar 2025 10:11am |
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| Surfsup007 Member Since: 02 Mar 2025 Location: Stoke Posts: 12 
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You sir, are a genius, and I am the village idiot! It refused to engage but when I feathered the clutch the transfer stick dropped into place. I do feel a bit stupid now! Thanks everyone for reading this and giving your advice. I took some pics so I’ll list out how I did it. Cheers Last edited by Surfsup007 on 15th Mar 2025 1:02pm. Edited 1 time in total |
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15th Mar 2025 11:20am |
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| Surfsup007 Member Since: 02 Mar 2025 Location: Stoke Posts: 12
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 Click image to enlarge It all started with some innocuous fettling, the bumper was rusty and I wanted to change out for a new one, I ended up cutting it off as it was rusted through, I also changed the air filter as I part of a service, removed a few sensors and gave them a clean. Then as above just thought I’d check it started ok, couldn’t be bothered to get in the car, yanked it out of gear whilst standing outside the car and started it, at which point it lurched forward appearing still to be in gear. There are other great how to’s on here but I thought I’d share my experience and photos, you can never have too many photos to refer to! Heres the how to i referred to: https://www.defender2.net/forum/topic60607...stuck+gear Here's my attempt: Last edited by Surfsup007 on 15th Mar 2025 12:00pm. Edited 1 time in total |
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15th Mar 2025 11:27am |
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| Surfsup007 Member Since: 02 Mar 2025 Location: Stoke Posts: 12
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thanks for taking the time to assist, looks like it was just me being stupid! |
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15th Mar 2025 11:42am |
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| Surfsup007 Member Since: 02 Mar 2025 Location: Stoke Posts: 12
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The first stage is the most fiddly, removing :
- The gear stick (this is simple prise apart the clips either side at the base and it just lifts off leaving you with the white stub stick.) - the carpet - the rubber bung around the sticks - the plastic shroud - these are a torx screws with attached sound deadening This now gives you good access to the top of the gearbox, next its time to remove all eight torx bolts holding down the gearstick and transfer box stick. Click image to enlarge Click image to enlarge Click image to enlarge |
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15th Mar 2025 12:08pm |
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| Surfsup007 Member Since: 02 Mar 2025 Location: Stoke Posts: 12
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Now that the torx bolts are removed, there's no need to fully remove the transfer box lever. To pull this to one side, its actually easier to reach under the cowling and disconnect the transfer box. Theres a clip and a rod, this worried me a little but it simply pulls off a sprung ball joint (see the clip bottom middle right in this pic: ) The transfer box stick can then be set to one side. Now that this is removed, it exposes the fourth bolt (13mm spanner/socket) for the cover plate.
Click image to enlarge |
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15th Mar 2025 12:17pm |
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| Surfsup007 Member Since: 02 Mar 2025 Location: Stoke Posts: 12
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Now the cover plate can be moved over to one side (don't lose the rubber boot!) and the detentes can be clearly seen.
As I'd just changed out the bumper, it left me with a couple of blocks of steel that I could use to create a makeshift stud puller. Click image to enlarge The advice on other threads is to tap the detente with an M6 tap and then use an M6 bolt or screw. I have an m6 thumb turn bolt lying around, so I used that. Unfortunately, the top of the detente is quite thin material, and in my case, this just pulled through the material in the head of the detente. In the end, I ended up just using mole grips, making them really tight on the detente - crushing the head a little and working it out with a rocking motion. Click image to enlarge This now gives access into the gearbox: Click image to enlarge |
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15th Mar 2025 12:30pm |
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| Surfsup007 Member Since: 02 Mar 2025 Location: Stoke Posts: 12
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Next up:
Jack up the car so that the passenger side wheel is just off the ground, handbrake off, you should feel the feel rotate a little and engage the gear if its stuck in gear. using a small flat head screwdriver, place it into the hole in the gearbox and tap the selector towards the front of the car, this didnt work for me initially, but I tried a few times and eventually I felt it click forward, checked the front wheel and it spun freely, youre now in neutral (HORRAY!) Its now time to replace the detente. There's a real difference in the strength of the spring between the two; you can manually press in the ball bearing on the old one but can't on the new one. Its recommended to put a drop of locktite on the detente prior to fitting, place it in the hole and drift it in using a soft faced hammer or as I did I used a brass compressor fitting as a drift. The kit with the new detentes includes 3No, one large one and two smaller ones, and is around £99 I opted not to replace the other detente just now but you can replace both. Click image to enlarge Click image to enlarge Last edited by Surfsup007 on 15th Mar 2025 12:58pm. Edited 1 time in total |
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15th Mar 2025 12:44pm |
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| Surfsup007 Member Since: 02 Mar 2025 Location: Stoke Posts: 12
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Putting it all back together is basically the reverse of the above;
for me, in putting the stick back together, I found that the ball was cracked, so I opted to fit a slick shift kit. I have to say it has transformed the way it feels—real positive action, slightly shorter throw but it all feels a lot tighter without the play. I can recommend it. https://www.onlinegearboxparts.com/product...lickshift/ Click image to enlarge And then when it was all back together I turn the key and just heard a grinding noise on lifting the clutch, I was so gutted! As pointed out above, I'd knocked the transfer box stick into neutral - at the time I put all my tools away in a huff!! Feel a bit stupid for missing that, but Im so glad its fixed!! |
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15th Mar 2025 12:54pm |
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| jim4244 Member Since: 13 Apr 2014 Location: Bedfordshire Posts: 905  
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Great write up
Jim |
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15th Mar 2025 1:03pm |
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| Surfsup007 Member Since: 02 Mar 2025 Location: Stoke Posts: 12
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Cheers Jim
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15th Mar 2025 1:05pm |
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| andy63 Member Since: 30 Jun 2023 Location: north east Posts: 679
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👍👏👏.. well done
and it all helps in the understanding of these trucks..and a bit pleasure in knowing you did it and learned something.. |
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15th Mar 2025 2:45pm |
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| Surfsup007 Member Since: 02 Mar 2025 Location: Stoke Posts: 12
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Cheers Andy 👍
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15th Mar 2025 3:15pm |
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