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hank



Member Since: 12 Sep 2016
Location: South Wales/Middle East
Posts: 1147

Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

There has been a slight oil weep from the transfer box since the day I had the Defender. It looked to be coming from the intermediate shaft/case as is common so I wasn't overly rushed to look at it.

More recently the rear output seal had started leaking so I took it as the nudge I needed to get the transfer box off for a rebuild.

Removing is a bit of a faff with a couple of fiddly connectors and linkages to disconnect. The floor panel beneath the cubby box provides good access. Propshafts disconnected and exhaust split after the catalytic converter. Handbrake drum removed and finally unbolt it. My Dad was helping so we slung the box with rope and as I unbolted/slid it off the gearbox output shaft he lowered it to ground from above. Seemed to work ok but I think we will need more help to get it back in!

We re-cased the transfer box into an Ashcroft sleeved case with an Ashcroft master rebuild kit. Took the opportunity to upgrade the diff with an Ashcroft HD cross pin. I found some copper shards in the old box and it turned out that the diff planet gear thrust washers had disintegrated to nothing. This was causing the planet gears to run at the outermost edge of the shaft resulting in slop in the gear mesh. New ones fitted and all good - hoping this tightens a little driveline backlash too!

Overall not too bad a job, just following the rebuild manual which is very detailed. Time consuming though and mostly cleaning

Was pleased to see the Ashcroft gearbox output shaft was still looking spot on after being fitted for three years!

HD cross pin

Click image to enlarge


Sleeved casing

Click image to enlarge


Rebuilt rear

Click image to enlarge


Rebuilt front

Click image to enlarge
 > 110 XS Double Cab
> Instagram @simonlanemind

Post #846707 28th Jul 2020 5:40pm
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hank



Member Since: 12 Sep 2016
Location: South Wales/Middle East
Posts: 1147

Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Transfer box is back in the Defender. Serious improvement in terms of backlash and leak free!

Refitting was relatively straightforward... We tied rope around the box and lifted through the floor panel while I aligned it onto the gearbox shaft from underneath and put a bolt in.

Trickiest parts of the whole job I found were refitting the diff lock selector arm and tightening the prop shaft nuts - so fiddly!

One more pic of the ashcroft output shaft to close that chapter


Click image to enlarge
 > 110 XS Double Cab
> Instagram @simonlanemind

Post #847030 30th Jul 2020 1:04pm
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Grenadier



Member Since: 23 Jul 2014
Location: The foot of Mont Blanc...
Posts: 4650

France 2011 Defender 110 Puma 2.4 DCPU Corris Grey

Hank, do you think it was the Ashcroft rebuild kit, output shaft or both, that really reduced the backlash? The rebuild kit is quite a job, whereas the output shaft is a common upgrade I’m thinking of DIYing. Thumbs Up Monsieur Le Grenadier

I've not been everywhere, but it's on my list.....

2011 Puma 110DC - Corris Grey

Post #847165 31st Jul 2020 7:08am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 11666

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

The breakdown of the centre diff thrust washers will have resulted in a lot of backlash in this box.

Post #847188 31st Jul 2020 8:51am
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Grenadier



Member Since: 23 Jul 2014
Location: The foot of Mont Blanc...
Posts: 4650

France 2011 Defender 110 Puma 2.4 DCPU Corris Grey

Thumbs Up Monsieur Le Grenadier

I've not been everywhere, but it's on my list.....

2011 Puma 110DC - Corris Grey

Post #847403 1st Aug 2020 7:32am
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hank



Member Since: 12 Sep 2016
Location: South Wales/Middle East
Posts: 1147

Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

As black wolf says the backlash was, without a doubt, coming from the lack of washers in the diff planetary gears which would have allowed the planetary gears to run further "out" (for want of a better term) where they wouldn't mesh properly due to being bevel gears.

The output shaft is only really an issue if you have a leak > 110 XS Double Cab
> Instagram @simonlanemind

Post #847766 3rd Aug 2020 11:50am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 11666

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

hank wrote:
...The output shaft is only really an issue if you have a leak



... or if you have no drive!

Post #847809 3rd Aug 2020 2:59pm
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hank



Member Since: 12 Sep 2016
Location: South Wales/Middle East
Posts: 1147

Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

Hahaha true dat > 110 XS Double Cab
> Instagram @simonlanemind

Post #847831 3rd Aug 2020 5:27pm
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