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InternationalDBA



Member Since: 18 Feb 2018
Location: West Sussex
Posts: 41

United Kingdom 2008 Defender 110 Puma 2.4 SW Stornoway Grey
Transfer box operating lever
The attached photo shows the operating mechanism for the transfer box of my 2008 Defender.
I'm reconnecting it following a chassis swap.
If you are familiar with this you will recognise the end of the rod which goes down to select low or high ratio.
You will also see the bar which goes down to lock the centre differential if required.
The problem is that (if you zoom in) you will see that the cup at the end of the low / high ratio rod is fouling on the bar which operates the differential.
How can I fix this?
Do I need a new cup at the end of the low/high ratio selector rod or do I need a whole new rod?


Click image to enlarge
Post #1074737 4th Sep 2025 5:14pm
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andy63



Member Since: 30 Jun 2023
Location: north east
Posts: 823

United Kingdom 
is it possible that rod is the wrong way round.. ie the ball socket at that end should be a smaller one
Post #1074743 4th Sep 2025 7:11pm
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InternationalDBA



Member Since: 18 Feb 2018
Location: West Sussex
Posts: 41

United Kingdom 2008 Defender 110 Puma 2.4 SW Stornoway Grey
Is it the wrong way round?
No, I don't think it is the wrong way round as I never removed the rod from the transfer box.
I only removed it from the end attached to the gear lever.
Post #1074783 5th Sep 2025 9:15am
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andy63



Member Since: 30 Jun 2023
Location: north east
Posts: 823

United Kingdom 
OK.. but AFAIK the disconnect fitting ( ie the little push button ) is normally on the transfare box lever.. im unable to check my vehicle but hopefully someone will respond..
Post #1074788 5th Sep 2025 10:58am
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piechipsandpeas



Member Since: 12 May 2021
Location: Albany, Western Australia
Posts: 234

Australia 2013 Defender 110 Puma 2.2 SW Indus Silver
I happen to have mine out of the car at the moment. I think Andy63 is correct and the rod should be the other way around.


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Post #1074807 5th Sep 2025 12:46pm
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Ianh



Member Since: 17 Sep 2018
Location: Essex
Posts: 2516

United Kingdom 
Yep as per Andy and piechipsandpeas say that’s the wrong way around, at some point someone has inadvertently done this.

Ps, treat this part with care as it’s not available separately, if it breaks and you can’t get a used part you need to buy the whole leaver and mechanism (inc this part) at a high cost !!!
Post #1074808 5th Sep 2025 12:53pm
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InternationalDBA



Member Since: 18 Feb 2018
Location: West Sussex
Posts: 41

United Kingdom 2008 Defender 110 Puma 2.4 SW Stornoway Grey
It was the wrong way round
This is strange.
I bought the vehicle new in 2008 to drive to work and tow a large caravan.
It has never been offroad but in 2010 I did need to go slowly down a short steep hill covered in hard packed snow.
I used 1st gear + low ratio + diff lock to drive down without using the brakes.
I vaguely remember having trouble selecting the low ratio and diff lock but did not investigate further at the time.
The low ratio and diff lock have not been used since then.
I know this for sure as nobody else drives the vehicle.
The vehicle was maintained by the main agent until 75,000 miles then by an independent garage until 120,000 miles.
I have done extensive car maintenance in the past so I have done everything since then.
It got to just over 160,000 miles and the side steps, bumper and chassis were well past their best so I decided to change them all.
It seems to me that this rod may have been fitted the wrong way round when the vehicle was built because AFAIK, nobody has had any reason to remove it.
Either way, I swapped the rod round as suggested and the selector now works perfectly.
Thank you to everybody who replied.
Post #1074824 5th Sep 2025 5:55pm
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Ianh



Member Since: 17 Sep 2018
Location: Essex
Posts: 2516

United Kingdom 
That’s priceless from JLR, I expect it was assembled on a Friday after the fitter and quality control guy had been on a big liquid lunch down the pub.

Good it’s all working ok now Thumbs Up

Ps , the main reasons for it being touched would be to remove the transfer case, for say an output shaft replacement or to change a seal , or for a clutch change or gearbox or crank seal change.
Even then you only remove the transfer box end ! So I can’t think of any reason it would have ended up fitted the wrong way
Post #1074830 5th Sep 2025 7:42pm
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