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keith



Member Since: 15 Aug 2012
Location: Edinburgh
Posts: 2264

Scotland 
Don’t travel on Fri 13th they said.
The pics tell their own story…..
The simple 1hr drive, right? I battled through a thunderstorm, hail, torrential downpour, Friday M8 traffic and still was doomed to fail. Cruise control set at 60 and…BANG, with the immediate smell of unmistakable hot gear oil. Only 3 miles from services I limped on and got off the motorway to a puddle of gearbox oil. AA arrived within 1hr, recovery within 2 hrs and still waiting on Enterprise to bring another car. The main gearbox has blown out the filler plug 😮 so hopefully Havnt lost too much oil.


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Last edited by keith on 13th Jun 2025 4:52pm. Edited 1 time in total
Post #1069642 13th Jun 2025 4:28pm
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Caterham



Member Since: 06 Nov 2008
Location: Birmingham
Posts: 6346

England 2011 Defender 110 Puma 2.4 XS CSW Stornoway Grey
how on earth does that happen?

it least you didn't have a full house heading off on your holidays this time?
sorry to hear this. try and have a nice sunny weekend. Thumbs Up
Post #1069643 13th Jun 2025 4:46pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17822

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Very strange and disturbing. Even if the gearbox could pressurise (doubtful since it is vented to atmosphere) I'd expect it to blow excess pressure and oil past the seals long before it blows out the filler plug.

Are you sure it's a plug that's blown out not one of the selector fork fulcrums? It was clearly drivable afterwards if you limped to the services.

I worry that there may have been a catastrophic internal event behind this. Please keep us informed.
Post #1069644 13th Jun 2025 4:55pm
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keith



Member Since: 15 Aug 2012
Location: Edinburgh
Posts: 2264

Scotland 
Lightning doesn’t strike twice, does it? It does if you drive a Landrover. Infact I’m sure there’s a big ⚡️ cloud never far away when you turn a defender ignition key 😂
There should be a forum competition to see who’s been on the recovery truck the most 🙄
Post #1069645 13th Jun 2025 4:58pm
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keith



Member Since: 15 Aug 2012
Location: Edinburgh
Posts: 2264

Scotland 
BW… I have no problem selecting any gear. I drove on for 5 miles before services with no symptoms other than hot oil on the exhaust. Upon visual inspection, other than a big stinking mess with chassis, gearbox, wheels and back door covered in gear oil, the only thing to see is the hole where the filler plug goes. Iv not had it off anytime recently.
Post #1069647 13th Jun 2025 5:05pm
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Screbble



Member Since: 26 Apr 2015
Location: Lancashire
Posts: 2268

United Kingdom 2004 Defender 90 Td5 XS CSW Zambezi Silver
I’m sorry to hear this. I’d forgotten the date until I read your post.

Like others I don’t understand what has happened here. How would the gearbox become pressurised, and even if it did, how would it blow out the filler plug?

Whatever it is, I Hope it’s a quick and inexpensive fix Thumbs Up
Post #1069651 13th Jun 2025 5:16pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 17822

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Weird, fingers crossed there's no other damage.

Could the bang have been the plug being thrown against the vehicle by the front prop shaft, I wonder. Does the thread in the hole look ok?

Is the vehicle possessed by demons?
Post #1069652 13th Jun 2025 5:25pm
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keith



Member Since: 15 Aug 2012
Location: Edinburgh
Posts: 2264

Scotland 
It’ll be Monday before it goes up on the ramps and I can get a look underneath. Iv ordered a filler plug already with the hope that’s what it is but the cause is unknown till Examination. Iv done dozens of box oil changes but could I have not done the plug up tightly the last time …( 5 months ago ) mistakes happen uh!
Post #1069654 13th Jun 2025 5:32pm
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jbcollier



Member Since: 29 Apr 2024
Location: Edmonton AB
Posts: 247

Canada 2009 Defender 110 Puma 2.4 SW Alpine White
You used the word "BANG." Can you explain further?

I assume that means there was a significant noise before the hot gear oil smell. That would seem to imply that the filler plug didn't loosen but was forcibly ejected. Are the threads in the case still there?
Post #1069656 13th Jun 2025 6:02pm
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keith



Member Since: 15 Aug 2012
Location: Edinburgh
Posts: 2264

Scotland 
Great question and one I have thought about because it wasn’t me lying on my back in a pool of gear oil looking up. It was the AA driver and I didn’t have the foresight to ask him before he drove off. I’ll have to wait till Monday. It was a 2 stage noise, the bang/pop and then the tinkle as it dropped hitting the exhaust.
Post #1069659 13th Jun 2025 6:17pm
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Screbble



Member Since: 26 Apr 2015
Location: Lancashire
Posts: 2268

United Kingdom 2004 Defender 90 Td5 XS CSW Zambezi Silver
Whatever it was/is let’s hope it’s a painless solution for you 👍
Post #1069663 13th Jun 2025 6:39pm
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Caterham



Member Since: 06 Nov 2008
Location: Birmingham
Posts: 6346

England 2011 Defender 110 Puma 2.4 XS CSW Stornoway Grey
agreed Thumbs Up
Post #1069698 14th Jun 2025 10:36am
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custom90



Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20882

United Kingdom 
I found when I last needed to access the LT230 filler that is was hand tight, aka loose enough to turn by hand not even torqued, plus it seemed to have no thread sealant left.
I know that’s the LT230 filler. And not the MT82. But when I fitted the plugs on the MT82 on mine, I applied some Hylomar blue to the threads then torqued to spec.

I think you’d be surprised how, if threads are clean, but torqued to spec they can still come loose,
a product like Hylomar blue is good for preventing that.
The good thing is it’s the filler plug, and not the drain, so fingers crossed you’ll be okay.

What filler plug was it a genuine one or a different one? _\Hennessey|Venom| F5/___
___\⭐️Lone|Star|State/___
____\We|Will|Win/___

____/🇬🇧🇺🇸\____
_//*⛽️🛢️⚙️🧰*\\_
Post #1069709 14th Jun 2025 2:19pm
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andy63



Member Since: 30 Jun 2023
Location: north east
Posts: 774

United Kingdom 
Am I right in thinking the transfare box filler plug is a different animal to the main box filler plug..
The transfare filler plug is in a small taper..ie outside diam a mm larger than the inner threads..
The mt82 is done up to a tightish stop..you need to take a bit more care with the transfare box filler plug..👍
Post #1069713 14th Jun 2025 5:36pm
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Screbble



Member Since: 26 Apr 2015
Location: Lancashire
Posts: 2268

United Kingdom 2004 Defender 90 Td5 XS CSW Zambezi Silver
The most important thing is that you get it sorted Keith.
The second most important thing is I need to know if your meal deal was any good 👍
Post #1069723 14th Jun 2025 6:33pm
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