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BenB8man



Member Since: 22 Mar 2017
Location: Norfolk
Posts: 328

United Kingdom 2010 Defender 110 Puma 2.4 DCPU Stornoway Grey
Gearbox leak

As the subject states, it appears that I have sprung a leak on the way into work today. I've taken a picture that shows that it seems to be coming from the side of the box. I've previously taken the gearbox and transferbox off for a clutch change and adaptor shaft but that was probably 6 months ago, so nothing immediate after that. Any ideas which seal it could be?

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Thanks in advance!

Ben

Post #701418 17th Apr 2018 1:56am
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BenB8man



Member Since: 22 Mar 2017
Location: Norfolk
Posts: 328

United Kingdom 2010 Defender 110 Puma 2.4 DCPU Stornoway Grey

This may be useful..

Post #701419 17th Apr 2018 2:37am
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zsd-puma



Member Since: 09 Aug 2016
Location: Kent
Posts: 2720

United Kingdom 2010 Defender 110 Puma 2.4 USW Santorini Black

All you can do is clean it all off, then once it's dry take it for a short drive and recheck it again.

It might be that white plastic plug, but without cleaning it all off it's pretty much a guess.

When you fitted the Ashcroft shaft did you replace the gearbox oil and how much did you put it in?

Post #701462 17th Apr 2018 11:18am
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custom90steve



Member Since: 21 Jan 2010
Location: South West England
Posts: 17159

United Kingdom 2007 Defender 90 Puma 2.4 SW Stornoway Grey

I had that before my clutch was done a few years ago.
It's the gearbox to transfer box main oil seal, I think it's a gasket type as far as I'm aware of.
Quite cheap, but the problem is the transfer box has to be dropped to replace.

Could also be slight overfil of course too. Thumbs Up Made In GB. 🇬🇧

Watts ÷ Volts = Amps.
Amps X Volts = Watts

Post #701468 17th Apr 2018 11:36am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 10028

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

In the video it looks to me as though the fitting for the breather pipe is crooked, possibly cross-threaded?

There is no gasket between the gearbox and transfer box on a Puma, mainly because the main gearbox extension housing that bolts to the transfer box is an empty void with no lubricant (usually just rusty debris from the failing splined coupling it contains). There is an oil seal fitted in the transfer box which seals the input shaft, but if this was leaking it is unlikely that oil would get as high up the main box or as far forward along the main box. generally a leak from this will be all over the front of the transfer box.

It looks to me as though the source of the leak is somewhere in the vicinity of the main gearbox breather, and given that it looks skew-whiff it is the first thing I would check.

zsd-puma wrote:
When you fitted the Ashcroft shaft did you replace the gearbox oil and how much did you put it in?


You didn't make the mistake of filling it to the bottom of the filler plug orifice, by any chance?

Post #701469 17th Apr 2018 11:44am
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BenB8man



Member Since: 22 Mar 2017
Location: Norfolk
Posts: 328

United Kingdom 2010 Defender 110 Puma 2.4 DCPU Stornoway Grey

Thanks Gents.

Breather was my first thought too, I just don't understand how this much oil is coming out all of a sudden. I'll certainly give that a check first.

I've just done an oil change + diffs but haven't got round to doing the gearbox or transfer boxes yet so certainly not overfilled recently. Unless a blocked breather combined with PO overfilling may have caused this. I did not replace the gearbox oil when I did the shaft, should I have done? I lost barely a drop during fitting.

I did change the seals when I split the boxes, so I could have damaged them whilst fitting. Maybe they've just lasted 5k and have just gone. Looks like I may be taking it all out again Big Cry

I'll drop the oil in the next few days and give it a measure too, see if I've lost much.

Post #701497 17th Apr 2018 1:45pm
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neon1991



Member Since: 26 Mar 2018
Location: Colchester
Posts: 37

United Kingdom 2007 Defender 90 Puma 2.4 XS CSW Galway Green

my money's on a loose breather plug. as for replacing the gearbox oil. I would have thought that you'd have to add a bit more to make up for the stuff that ends up in the ashcroft jobbie.

Post #701521 17th Apr 2018 5:26pm
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zsd-puma



Member Since: 09 Aug 2016
Location: Kent
Posts: 2720

United Kingdom 2010 Defender 110 Puma 2.4 USW Santorini Black

There's no 'need' to change the oil when you did the shaft - I was just wondering if you had then perhaps you'd filled it to the filler plug. The amount that goes into the Ashcroft shaft is so minimal there's no need to compensate for it.

I'd still wash it all off and then have another look after a short drive, that normally gives a definitive location for the leak.

Post #701598 17th Apr 2018 8:56pm
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BenB8man



Member Since: 22 Mar 2017
Location: Norfolk
Posts: 328

United Kingdom 2010 Defender 110 Puma 2.4 DCPU Stornoway Grey

Ah ok. I'll give it a clean, drop and measure the quantity just to be sure and see if I can work out exactly where its coming from.

Any recommendations on cleaner for the job?

Post #701605 17th Apr 2018 9:57pm
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zsd-puma



Member Since: 09 Aug 2016
Location: Kent
Posts: 2720

United Kingdom 2010 Defender 110 Puma 2.4 USW Santorini Black

Comma Hyperclean. Failing that, Brake cleaner does a good job.

Post #701606 17th Apr 2018 10:05pm
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custom90steve



Member Since: 21 Jan 2010
Location: South West England
Posts: 17159

United Kingdom 2007 Defender 90 Puma 2.4 SW Stornoway Grey

blackwolf wrote:

There is no gasket between the gearbox and transfer box on a Puma, mainly because the main gearbox extension housing that bolts to the transfer box is an empty void with no lubricant (usually just rusty debris from the failing splined coupling it contains). There is an oil seal fitted in the transfer box which seals the input shaft, but if this was leaking it is unlikely that oil would get as high up the main box or as far forward along the main box. generally a leak from this will be all over the front of the transfer box.

The more I think of it of course you are right, not sure what I was thinking. Rolling Eyes
It must have been that oil seal on mine you mention that went.
As it migrated downwards to the lowest lip of the bell housing, hence me thinking that was the source.

The leak in this case must be up top as you mentioned seeing as it wouldn't really migrate up to the top from lower down.
If it is the breather, wonder how it happened? Confused

Holts brake cleaner or what ever does the job of cleaning up nicely.
Thumbs Up

Think I'll stick more to electrics than oily bits in future. Whistle
 Made In GB. 🇬🇧

Watts ÷ Volts = Amps.
Amps X Volts = Watts

Post #701623 17th Apr 2018 11:22pm
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BenB8man



Member Since: 22 Mar 2017
Location: Norfolk
Posts: 328

United Kingdom 2010 Defender 110 Puma 2.4 DCPU Stornoway Grey

I know this is digging up an old thread, but I feel I'm no closer to solving this mystery.

I've cleaned it all up a few times and I'm positive that its coming from the breather. I've just taken to a garage who have have a look too and are a little puzzled as to why oil is coming out the top.

The garage have blown out the breather (as its extended). That seemed all clear. The bolt with a hole through is was tight on and not cross threaded. The pipe that plugs into it was a tight fit and seems all in good condition.

We've added a copper washer to the bolt and put it back on but why(and how) on earth should so much oil be coming out the top?!

I've just changed the oil, and naturally as it's been leaking it was a little low. Since topping it back up with 2.2l (not using the 'filler plug') its leaking even more!

Any more ideas? I looked back at some of the photos from when I did the original clutch change with the box out and there was a dark oily mark around the breather plug but no leak, so its something that seems to be progressing. Shocked

I'm stumped.

Post #768800 16th Apr 2019 9:56am
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BenB8man



Member Since: 22 Mar 2017
Location: Norfolk
Posts: 328

United Kingdom 2010 Defender 110 Puma 2.4 DCPU Stornoway Grey

Ok, after some further diagnosis and poking around I believe I may have an oil contamination issue. Shocked

Do we have any oil experts in the forum or can anyone recommend a professional gear oil connoisseur. Its possible I may have caused the issues when installing the Ashcroft adapter kit.

Not keen on taking everything out again, but its certainly looking that way.

Thanks

Post #769353 20th Apr 2019 3:45pm
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BenB8man



Member Since: 22 Mar 2017
Location: Norfolk
Posts: 328

United Kingdom 2010 Defender 110 Puma 2.4 DCPU Stornoway Grey

Ok, I'm still at a loss on this one.

After asking around it appears that its pretty unlikely that I've contaminated my oil with grease from the Ashcroft kit, as it happened straight after a oil change. Its definitely dependent on the speed that I drive. A motorway run will cause a bigger leak than a slow drive around the countryside. I've checked the breathers are clear and blown them out with an airline. I've checked that its plugged tight into the top of the gearbox and taken out and inspected the through-bolt which the breather plugs into. All seems ok. The garage even tried putting a copper washer in there too. All seems OK but leak is still there.

I'm totally stumped. Next idea is to get a camera up there or strip the gearbox tunnel so I can see exactly what happens when i'm on a quick drive. Any ideas which would be easier? I was thinking of strapping a wireless camera up there but not sure what to go for.

Could excess heat be causing foaming of the oil? Any way I could get a temperature probe in there somewhere? What would normal temperatures be on a run?

I'm on the brink of dropping this off to a specialist to have them strip it down, so could get expensive fast. Even if the advice could help point them in the right direction it would be brilliant to get some ideas.

Thanks for your continued support Smile Bow down

Post #777173 12th Jun 2019 2:06am
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BenB8man



Member Since: 22 Mar 2017
Location: Norfolk
Posts: 328

United Kingdom 2010 Defender 110 Puma 2.4 DCPU Stornoway Grey

blackwolf wrote:
In the video it looks to me as though the fitting for the breather pipe is crooked, possibly cross-threaded?


It looks to me as though the source of the leak is somewhere in the vicinity of the main gearbox breather, and given that it looks skew-whiff it is the first thing I would check.



Thought I would just update this, in case anyone searches. Blackwolf, you must be used to being right by now, but here we are again. Bow down

Post #785979 9th Aug 2019 7:53pm
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