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BogMonster



Member Since: 05 Feb 2008
Location: Stanley
Posts: 389
Falkland Islands 2015 Defender 110 Puma 2.2 USW Corris Grey
MT82 gear lever adjustment?
Since getting my Puma I've always hated 3rd gear. It crunches most of the time when warm.

I've recently discovered by accident that the shift into 3rd seems better if you do a bit of a detour between 2nd and 3rd and take the lever slightly over from the sprung central position towards the 5/6 plane, before doing a wiggle and pushing it forward into 3rd. It seems fairly consistent and only needs a small movement past the centre position.

I presume somewhere in the top of the box there must be some arrangement similar to the bias springs/plate that breaks on the R380 box, my question is whether there is any adjustment/fiddle factor available on this to refine the alignment of the 3rd/4th plane? I feel that if the gate/bias springs could be moved slightly to the right it might fix the issue without having to do the funky wiggle going into gear. 4th is perfect every time so I don't want to upset that.

Any thoughts please? ---
2006 Defender 110 SW 300Tdi • 2011 Ford Ranger XLT crewcab • 2015 Defender 110 Station Wagon Utility TDCi
Post #882506 2nd Feb 2021 12:54am
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hank



Member Since: 12 Sep 2016
Location: South Wales
Posts: 2231
Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
I can't answer your question but I too have found that in between the 2nd to 3rd shift if you apply minor pressure towards 4th (kind of like an N shape shift) then the change into third is improved. I have mentioned it before here https://www.defender2.net/forum/topic61047.html

I always assumed it was something to do with synchromesh's and that moving towards 4th spins up the 4th synchro so that then when you change to 3rd it almost simulates a downchage in terms of gearbox shaft rotational speeds... But that's an absolute stab in the dark and likely completely wrong Laughing > 110 XS Double Cab
> Instagram @simonlanemind
Post #882541 2nd Feb 2021 10:05am
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BogMonster



Member Since: 05 Feb 2008
Location: Stanley
Posts: 389
Falkland Islands 2015 Defender 110 Puma 2.2 USW Corris Grey
Yeah, I have found the optimum pattern seems to be to stir it in a small clockwise circle (probably about half an inch in diameter at the top of the gear lever) around the middle point (where the lever would sit at rest) just before going in to 3rd. You may be right, little conversation among the synchros going something like:

2nd: "Calling third, get ready with the crunch ...over"
3rd: "Crunch on standby, ready when you are ... send, over"
2nd: "Oh sh**, he's going for 5th ... no 4th ... no ..."
3rd: "Ok, just going to pop for a coffee"
4th & 5th: "Wha ... whoah ... we're not ready"
...slides smoothly into 3rd....
3rd: "Dammit, he tricked us"

Maybe I need to just take the top off and finesse the alignment wiv a big ammer like on an R380 Laughing

It does infuriate me that the change on my R380 is miles better than the MT82.... ---
2006 Defender 110 SW 300Tdi • 2011 Ford Ranger XLT crewcab • 2015 Defender 110 Station Wagon Utility TDCi
Post #882558 2nd Feb 2021 11:10am
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Matt110



Member Since: 29 Jun 2014
Location: UK
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United Kingdom 
Rolling with laughter Rolling with laughter Only on a defender forum............. lol.
Post #882571 2nd Feb 2021 11:46am
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Roy5695



Member Since: 15 Feb 2014
Location: Cornwall
Posts: 1123
United Kingdom 2011 Defender 110 Puma 2.2 XS DCPU Indus Silver
There’s a sticky’s thread in the Puma section referencing some shims/locators that can be added to the gear housing to help the gear change 2011 Defender DCPU 2.2 - https://www.defender2.net/forum/topic30623.html

Instagram - @r22oyp

Roy
Post #882643 2nd Feb 2021 3:39pm
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jst



Member Since: 14 Jan 2008
Location: Taunton
Posts: 7687
2011 Defender 110 Puma 2.4 USW Stornoway Grey
Love it, made me smile Cheers

James
110 XS Utility
130 Puma Station wagon/camper (in the making)
90 Puma Hardtop
Post #882647 2nd Feb 2021 3:47pm
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hank



Member Since: 12 Sep 2016
Location: South Wales
Posts: 2231
Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Roy5695 wrote:
There’s a sticky’s thread in the Puma section referencing some shims/locators that can be added to the gear housing to help the gear change


This one... https://www.defender2.net/forum/topic29132.html

I have fitted these shims and whilst they provided an improvement it did not completely cure the issue. It seems to be common, there's a lot of complaints about it on Mustang forum's as the modern ones use/used the MT-82 gearbox > 110 XS Double Cab
> Instagram @simonlanemind
Post #882674 2nd Feb 2021 4:42pm
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BogMonster



Member Since: 05 Feb 2008
Location: Stanley
Posts: 389
Falkland Islands 2015 Defender 110 Puma 2.2 USW Corris Grey
Excellent, thanks Thumbs Up ---
2006 Defender 110 SW 300Tdi • 2011 Ford Ranger XLT crewcab • 2015 Defender 110 Station Wagon Utility TDCi
Post #883095 4th Feb 2021 10:43am
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 16879
United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
The WSM stipulates that a special alignment tool (see below) should be used to position the gear lever housing correctly when tightening it down on the box for the MT82.

I've never used the tool, but usually put the box in third (as I recall) and then position the housing so that the lever feel right, and that the 1-2, 3-4, and 5-6 movement planes feels smooth and correct, with the right amount of bias. This has worked for me on many occasions.

If you are having trouble, it might be worth loosening the housing and manoeuvring it a little to improve the shift. If you can find someone with the alignment tool, that might also be worth a shot.

This is the tool, tool number 308-561 "ALIGNER", a bargain for a JLR special tool at £7.45 from Bosch (but you need an account to buy from them):



The tool also appears in the Ford service tools catalogue, whether it is easier to buy a Ford tool than a JLR tools I don't know, my search seems to show that Ford tools are also supplied by Bosch so ends up in the same place.
Post #883115 4th Feb 2021 11:24am
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hank



Member Since: 12 Sep 2016
Location: South Wales
Posts: 2231
Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Previously I had always tightened down my gear lever/shifter in the neutral position...

This evening I slackened off the four bolts, selected third and gave the shifter mechanism a few taps around to release/reset any misalignment/tension then tightened the bolts back down.

Success, no crunch into third Thumbs Up

Wish I had been aware of the third gear process sooner! > 110 XS Double Cab
> Instagram @simonlanemind
Post #884585 10th Feb 2021 10:24pm
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Badger110



Member Since: 06 Feb 2018
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United Kingdom 2011 Defender 110 Puma 2.4 USW Buckingham Blue
Blackwolf is the optimum of information on Def2, he's like google for Defenders.
Post #884604 10th Feb 2021 11:35pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 16879
United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Thumbs Up

Always a pleasure to help.
Post #884607 10th Feb 2021 11:37pm
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BogMonster



Member Since: 05 Feb 2008
Location: Stanley
Posts: 389
Falkland Islands 2015 Defender 110 Puma 2.2 USW Corris Grey
hank wrote:
Previously I had always tightened down my gear lever/shifter in the neutral position...

This evening I slackened off the four bolts, selected third and gave the shifter mechanism a few taps around to release/reset any misalignment/tension then tightened the bolts back down.

Success, no crunch into third Thumbs Up

Wish I had been aware of the third gear process sooner!


That's the kind of fix I had in mind, thinking it could be just slap-happy assembly from day one, which might be rectified by some fettling.

The odd thing is that 4th is absolutely perfect and snicks in like it was made by Suzuki Laughing ---
2006 Defender 110 SW 300Tdi • 2011 Ford Ranger XLT crewcab • 2015 Defender 110 Station Wagon Utility TDCi
Post #884695 11th Feb 2021 11:22am
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hank



Member Since: 12 Sep 2016
Location: South Wales
Posts: 2231
Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Fourth was fine on mine. Think it was because you're already in plane from third

For me it was a bit notchy into first... second perfect.
Crunch into third, fourth fine.
Fifth and sixth were always ok.

But since going though the 'retightening in third' procedure no problems selecting first and no crunch into third. > 110 XS Double Cab
> Instagram @simonlanemind
Post #884700 11th Feb 2021 11:50am
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