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PAT303



Member Since: 25 Feb 2013
Location: Australia
Posts: 123

Australia 1998 Defender 110 300 Tdi SW Alpine White
Intermediate shaft O ring change
When changing the T/C intermediate shaft in the TDCi is it possible to change it by tapping the shaft out enough to expose the o ring and tapping it back in and tightening the nut to it's original position or is it better to replace the crush tube?.
Post #790061 2nd Sep 2019 11:47am
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o4dn



Member Since: 08 Jan 2010
Location: South West
Posts: 529

France 2009 Defender 90 Puma 2.4 SW Alaska White
The WSM states that the TB on the Puma uses a collapsible spacer, yet all the ones I've seen had a fix length spacer from factory, so should be fine... I guess. “A Land Rover immobilized is a moral defeat for the driver and bad publicity for the vehicle, […] it's up to you to do justice to your Land Rover!” - Land Rover Driving Technique.
--
2009 2.4 Puma Defender 90 SW
1979 Land Rover Series 3 88"
Post #790082 2nd Sep 2019 1:24pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 16808

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
TD5 and TDCi versions of the LT230 don't use crush tubes, they have select-to-fit rigid spacers. On these boxes provided that you don't changes the intermediate shaft bearings there should be no problem re-using the existing tube. If the box is very high mileage and the bearings are worn, the preload will have reduced through wear and will stay reduced on reassembly.

if you fit new bearings then you should either convert to the crush tube type spacer, or remeasure the intermediate gear assembly and bearing for a new select-to-fit spacer. The latter isn't difficult but does require a certain amount of slightly specialised measuring equipment (a surface place, micrometer, and suitable micrometer depth gauge).
Post #790083 2nd Sep 2019 1:30pm
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keef9t



Member Since: 13 Mar 2016
Location: manchester
Posts: 168

United Kingdom 2007 Defender 90 Puma 2.4 HT Stornoway Grey
So, is it possible to replace the 'O' ring by tapping out just enough to get at and then re-tightening up, on a Tdci Puma.
Post #790384 3rd Sep 2019 8:42pm
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blackwolf



Member Since: 03 Nov 2009
Location: South West England
Posts: 16808

United Kingdom 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Should be. Unfortunately you still have to remove the transfer box first.
Post #790408 3rd Sep 2019 9:27pm
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PAT303



Member Since: 25 Feb 2013
Location: Australia
Posts: 123

Australia 1998 Defender 110 300 Tdi SW Alpine White
Just an update, I slide the T/C back on 10mmx120mm bolts enough to get to the shaft, it was quite easy to do in the end, the original o ring was rock hard and squared off. Interesting enough the nut wasn't staked but a new o ring fitted, a lot of sealant applied, just on this I used permatec sealant that is made especially for use with oils that contain friction modifiers, this is the third time this job has been done and I'm thinking one of my issue's is the sealant is breaking down which isn't helping. Anyway it's sitting on my driveway waiting for the sealant to cure which it does completely after 24hrs and hopefully it will have no more leaks, I will give an update tomorrow.
Post #793904 18th Sep 2019 11:25pm
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PAT303



Member Since: 25 Feb 2013
Location: Australia
Posts: 123

Australia 1998 Defender 110 300 Tdi SW Alpine White
Miracles do happen, my transfer case is not leaking, YYEEESSSS.
Post #794628 22nd Sep 2019 10:54pm
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PAT303



Member Since: 25 Feb 2013
Location: Australia
Posts: 123

Australia 1998 Defender 110 300 Tdi SW Alpine White
Well that was short lived, damn thing is leaking just as bad as ever.
Post #803364 24th Nov 2019 5:18am
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hank



Member Since: 12 Sep 2016
Location: South Wales
Posts: 2217

Wales 2007 Defender 110 Puma 2.4 DCPU Stornoway Grey
Laughing have you considered sleeving the casing?

Appreciate this would require full strip down rather than the quick fix you had anticipated > 110 XS Double Cab
> Instagram @simonlanemind
Post #803365 24th Nov 2019 6:16am
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Retroanaconda



Member Since: 04 Jan 2012
Location: Scotland
Posts: 2519

Scotland 
Sleeved casing is the only proper fix I’m afraid. Been putting mine off for months but it’ll need doing at some point Sad
Post #803367 24th Nov 2019 7:23am
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Oldowner



Member Since: 26 Dec 2018
Location: South west
Posts: 597

United Kingdom 2007 Defender 90 Puma 2.4 HT Aintree Green
Every lt230 I have stripped down (20 plus) has had a degree of wear in the casing - the intermediate shaft hole doesn’t necessarily ovalise visibly however it always seems to have a groove worn in it from where the o ring seats, which prevents a new o ring from seating correctly.

Only real fix is sleeved case from Ashcroft. I fit a HD intermediate shaft too.
Post #803368 24th Nov 2019 7:31am
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Big Harold



Member Since: 09 Jul 2018
Location: nsw
Posts: 71

Australia 2015 Defender 130 Puma 2.2 HCPU Alpine White
PAT303 wrote:
Well that was short lived, damn thing is leaking just as bad as ever.

Pat there is a mod that installs a penny washer to seal the case.
Still requires the box to be stripped but it does not leak.
Mark
Post #803373 24th Nov 2019 8:29am
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PAT303



Member Since: 25 Feb 2013
Location: Australia
Posts: 123

Australia 1998 Defender 110 300 Tdi SW Alpine White
Mate, where can I get one of those penny washers
Post #803458 24th Nov 2019 11:06pm
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PAT303



Member Since: 25 Feb 2013
Location: Australia
Posts: 123

Australia 1998 Defender 110 300 Tdi SW Alpine White
Oldowner wrote:
Every lt230 I have stripped down (20 plus) has had a degree of wear in the casing - the intermediate shaft hole doesn’t necessarily ovalise visibly however it always seems to have a groove worn in it from where the o ring seats, which prevents a new o ring from seating correctly.

Only real fix is sleeved case from Ashcroft. I fit a HD intermediate shaft too.


I was hoping I could get it to seal until rebuild time, I was even thinking of filling it with mineral oil instead of synthetic and change it more often.
Post #803459 24th Nov 2019 11:09pm
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Big Harold



Member Since: 09 Jul 2018
Location: nsw
Posts: 71

Australia 2015 Defender 130 Puma 2.2 HCPU Alpine White
PAT303 wrote:
Mate, where can I get one of those penny washers

https://www.allfourx4.com.au/?cawelaid=720...BcQAvD_BwE

Part# NGCP3150 Core, plug dome $10
The case needs a small step machined into it and I took a couple of mm off the end of the Intermediate shaft.
Mark
Post #803463 24th Nov 2019 11:33pm
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