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Froglaise



Member Since: 24 Sep 2016
Location: left forum
Posts: 212

Dropping the boxes for clutch change
So I've decided to drop the gear & transfer boxes out for a clutch change before a spring works lose on the 50k miles plate that's in there now (that got decidedly louder over Christmas trip). In addition to the clutch, crb, valve, adapter, slave cylinder I'll be fitting an Ashcroft rear output shaft (already ordered) which I'll fit regardless of originals condition.

Any recommendations of other jobs worth doing at same time?

Even though it only covers up to TD5 engine/box, is the Haynes manual worth having about during this? Think I'll buy one anyway that said.
Post #590656 6th Jan 2017 10:45am
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miker



Member Since: 13 Sep 2015
Location: Surrey
Posts: 1758

United Kingdom 1999 Defender 110 Td5 CSW Rioja Red
Haven't dealt with a Puma, but have had the engine out and dropped the box on my TD5.

Wouldn't bother with a Haynes manual, it's all very much visible! Just heavy and awkard
Post #590673 6th Jan 2017 11:42am
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TopQ1967



Member Since: 14 Feb 2012
Location: Veghel
Posts: 226

Netherlands 2012 Defender 130 Puma 2.2 HCPU Buckingham Blue
Gearbox complete out, or just move backwards?
The strugle with the DPF was my main problem.

Check and protect against rust.

When I checked there was rust between the detachable crossmember and chassis.
Also easy to get above the gearbox.
I cleaned everything and used Bilthamber products to prevent.

Check if ther is oil under the flywheel. This could mean a folty rear crank seal.

If you take the gearbox out, it is just a small extra exersise to check the output shaft that go's in the LT230 and give it a lick of grease.
Post #590678 6th Jan 2017 12:06pm
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Froglaise



Member Since: 24 Sep 2016
Location: left forum
Posts: 212

I'm going to drop it all the way out..give me a chance to get to know things better for any future work. Mines a 2.4 so no DPF to worry about.

Rust checking for sure and i think I'll do some sound deadening around the transmission and seat boxes while I'm at it.
Post #590724 6th Jan 2017 3:04pm
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grafty99



Member Since: 15 Aug 2012
Location: North Devon
Posts: 4784

United Kingdom 2002 Defender 90 Td5 HT Caledonian Blue
I did the clutch on my 90 and regretted not taking the engine out. In retrospect I think it would have been the easier route but can't comment on weather it actually is as I've not done it that way Thumbs Up 2002 90 Td5 Station Wagon
1990 Vogue SE
Triumph Tiger Explorer 1200
Td5 90 Thread http://www.defender2.net/forum/topic50767.html
Tdi 110 Thread https://www.defender2.net/forum/topic69562.html
RRC Thread http://www.defender2.net/forum/topic54492.html
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Post #590743 6th Jan 2017 4:18pm
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jst



Member Since: 14 Jan 2008
Location: Taunton
Posts: 7664

2011 Defender 110 Puma 2.4 USW Stornoway Grey
i did my 2.4 with t box and g box out together. all bell housing bolts can be done without taking any flooring/tunnels out just need to disconnect the gears sticks which is quite visible and obvious when you take the rubber cover off.

may need impact gun to get the nut/bolt off holding the intermediate shaft in place (i think- was more than 4 sleeps ago i did it!)

all pretty straight fwd, two people one day job with DIY tools. Cheers

James
110 XS Utility
130 Puma Station wagon/camper (in the making)
90 Puma Hardtop
Post #590745 6th Jan 2017 4:28pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 16807

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
There is a great deal less to disconnect and reconnect if you remove the transmission rather than the engine.
Post #590753 6th Jan 2017 4:47pm
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miker



Member Since: 13 Sep 2015
Location: Surrey
Posts: 1758

United Kingdom 1999 Defender 110 Td5 CSW Rioja Red
Yeah I'd go box out rather than engine out.
Post #590759 6th Jan 2017 4:53pm
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Froglaise



Member Since: 24 Sep 2016
Location: left forum
Posts: 212

I was tempted to go the engine out route, and at some point I'll find an excuse to do that but I'm curious to get to know the transmission so I'm going to get on it tomorrow.
Post #590929 7th Jan 2017 11:35am
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