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Home > Puma (Tdci) > Gear change noises !
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Ianh



Member Since: 17 Sep 2018
Location: Essex
Posts: 2524
United Kingdom 
Lightning, I’m aware you have ordered a good pump to refill the gearbox, which if cleaned correctly is also good for filling the transfer box and diffs with their spec oils.

However if anyone else wants to know of a cheap and accurate method to fill the gearbox, then a 1.2 metre length of 12mm Outside diameter clear plastic pipe does the job nicely. Just feed it from the engine bay , under the body and into the fill hole of the gearbox ensuring you hang it so it’s supported with no dips. Stick a funnel in the engine bay end and pore the correct measured amount of oil into the funnel. About £5 -10 in total. I purchased a 1.5m length and use the 300mm cutoff length with funnel for filling the transfer and diffs.
Post #1077406 13th Oct 2025 4:15pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 18009
United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
By clang I mean, I suppose, thud. Make sure the pedal is fully down.
Post #1077409 13th Oct 2025 4:37pm
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lightning



Member Since: 23 Apr 2009
Location: High Peak, Derbyshire
Posts: 3483
United Kingdom 
Yeah, now l've cut away the corner of the heavy duty floor mat, l can feel the pedal hitting the end stop.



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Post #1077416 13th Oct 2025 6:45pm
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Dinnu



Member Since: 24 Dec 2019
Location: Lija
Posts: 3638
Malta 2012 Defender 90 Puma 2.2 CSW Santorini Black
On later vehicles, the clutch pedal box has a bolt to limit the down movement of the pedal. Thats the thud that you should hear. Only very early vehicles had the foot well as a limit.

As for master cylinders, I had what supposedly been a highly regarded brand (with its associated price) fail in just 8 months. When I opened it up, I found a burr along the top of the piston (just beneath the seal) that gouged the bore beyond a possible rebuild repair. It was always hard for me to get more than 2 years - locally need to use the clutch A LOT until I modified the piston to expand the seals a bit more. It made a massive difference.

Not done to the Puma yet, but on my old 90 I am using dot5, not to be mistaken with dot5.1, which is silicone based. As it will eventually leak, at least I do not have a mess to the paintwork. Dot4 is highly corrosive. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing
2012 90 CSW, 2.2TDCI, Santorini Black
Post #1077420 13th Oct 2025 8:22pm
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