Defender Puma Output shaft





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  1. #1
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    Default Defender Puma Output shaft

    About 5 years ago the gearbox output shaft splines on my Puma stripped just outside Moremi North Gate and with a lot of hassle and cost we managed to get towed into Maun. A local mechanic replaced the shaft with a "good condition" one which got us back to Thabazimbi before stripping again. A friend came and towed me home from there (in a Land Cruiser nogal). The entire unit was then replaced with a new one from Land Rover by a reputable company and greased and sealed according to LR instructions to prevent fretting of the splines. However it has always worried me and last year I imported a redesigned unit from Ashcroft which bleeds a bit of gearbox oil off to lubricate the splines. I finally got round to fitting it and was shocked at the condition of the splines in the old shaft I removed. The seal which is supposed to hold the grease in was loose and there was no sign of any grease left. The shaft which is supposed to be held in position by a spring clip had unclipped and moved towards the transfer box until its shoulder butted up against the input gear. Only half the splines were now engaging and another catastrophic failure was imminent. The shaft has done 50000 km since replacement. I will try to attach a pic of the shaft splines to show the wear. What a horrible design from Land Rover. The Ashcroft unit is beautifully designed and machined and hopefully will solve this serious flaw which Land Rover never bothered to sort out. Some Puma's clock up high mileage without a failure, it would be interesting to know why.
    I read that there is a small hole between the extension shaft housing and transfer box and if this has a red film around it fretting of the splines is taking place. The fretted metal powder is then oxidizing and leaking out causing the film. Another warning sign is a lot of backlash in the drive train.
    Hope this helps any Puma owners out there from getting stranded.

    Alan
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    2010 Defender Puma

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  3. #2
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    Default Re: Defender Puma Output shaft

    And we trust these people to engineer the New Defender?
    Jakes Louw
    2012 Jeep Sahara Unlimited 3.6 V6
    Percivamus

  4. #3
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    Default Re: Defender Puma Output shaft

    Quote Originally Posted by jelo View Post
    And we trust these people to engineer the New Defender?
    That's why there had to be a new Defender designed though.

    The old one had to be patched up to keep it going with all the regulations. Patch jobs never work properly, be it a Lexus motor in a Disco3 or Boeing 737 Max

    The peak of Defender was 200/300 Tdi maybe Td5. Was downhill from there.
    Last edited by Byron; 2020/05/04 at 08:45 PM.
    Discovery Sport 2.0i D
    Defender 90 LE Puma 2.2TDCI
    Defender 110 DC Td5 (life partners)
    Discovery 1 200 Tdi Auto

  5. #4
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    Default Re: Defender Puma Output shaft

    No one will ever know why they went fine spline, it defies logic, we use that real nasty sticky type grease when they're replaced, touch wood no returns.....so far
    30 years experience and knowledge certainly out weighs a 5min keyboard bashing on google
    Love's electrickery stuff and problems related to it as long as it dont go bang cos then its f......
    NO REPLACEMENT FOR DISPLACEMENT
    A V8 is where thunder is made
    100%WEE

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  7. #5
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    Default Re: Defender Puma Output shaft

    gents, what's the latest on an upgraded output shaft?


    Ashcroft still the one to go for, or is there another kit that's a bit kinder on the wallet?


    thanks
    2010 Defender Puma 90 + BAS remap + Alive IC + Slickshift + Ashcroft ATB rear
    2015 Range Rover Sport Supercharged V8 HSE Dynamic



    Discovery 4 Workshop Manual: https://bit.ly/2zZ1en9

    Defender Puma Workshop Manual: https://bit.ly/2zXrtKO
    Range Rover/Sport L320/L322/L494 Workshop Manual: https://bit.ly/2zc58JQ

  8. #6
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    Default Re: Defender Puma Output shaft

    I have the ashcroft one no issues, seems to have proved itself. There is a new option from LOF clutches in the UK.

    https://lofclutches.com/?s=Shaft&pos...&type_aws=true
    Quote Originally Posted by Orxy View Post
    gents, what's the latest on an upgraded output shaft?


    Ashcroft still the one to go for, or is there another kit that's a bit kinder on the wallet?


    thanks
    2010 Defender Puma 110
    Bushlapa Boskriek B472

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  10. #7
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    Default Re: Defender Puma Output shaft

    Quote Originally Posted by Ontdekker View Post
    I have the ashcroft one no issues, seems to have proved itself. There is a new option from LOF clutches in the UK.

    https://lofclutches.com/?s=Shaft&pos...&type_aws=true
    Thanks, the LOF one looks great, but they're out of stock...
    2010 Defender Puma 90 + BAS remap + Alive IC + Slickshift + Ashcroft ATB rear
    2015 Range Rover Sport Supercharged V8 HSE Dynamic



    Discovery 4 Workshop Manual: https://bit.ly/2zZ1en9

    Defender Puma Workshop Manual: https://bit.ly/2zXrtKO
    Range Rover/Sport L320/L322/L494 Workshop Manual: https://bit.ly/2zc58JQ

  11. #8
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    Default Re: Defender Puma Output shaft

    sjoe, a bit of transfer box TLC is going to cost quite a lot...

    Click image for larger version. 

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ID:	589335
    2010 Defender Puma 90 + BAS remap + Alive IC + Slickshift + Ashcroft ATB rear
    2015 Range Rover Sport Supercharged V8 HSE Dynamic



    Discovery 4 Workshop Manual: https://bit.ly/2zZ1en9

    Defender Puma Workshop Manual: https://bit.ly/2zXrtKO
    Range Rover/Sport L320/L322/L494 Workshop Manual: https://bit.ly/2zc58JQ

  12. #9
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    Default Re: Defender Puma Output shaft

    Quote Originally Posted by Orxy View Post
    sjoe, a bit of transfer box TLC is going to cost quite a lot...

    Click image for larger version. 

Name:	ashcroft.JPG 
Views:	17 
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ID:	589335
    Rather do the LT230 ATB, that's what I did on my 90. Stronger and you get another ATB.
    Discovery Sport 2.0i D
    Defender 90 LE Puma 2.2TDCI
    Defender 110 DC Td5 (life partners)
    Discovery 1 200 Tdi Auto

  13. #10
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    Default Re: Defender Puma Output shaft

    Quote Originally Posted by Byron View Post
    Rather do the LT230 ATB, that's what I did on my 90. Stronger and you get another ATB.
    I thought about that, but the centre ATB won't prevent the output shaft from stripping?
    2010 Defender Puma 90 + BAS remap + Alive IC + Slickshift + Ashcroft ATB rear
    2015 Range Rover Sport Supercharged V8 HSE Dynamic



    Discovery 4 Workshop Manual: https://bit.ly/2zZ1en9

    Defender Puma Workshop Manual: https://bit.ly/2zXrtKO
    Range Rover/Sport L320/L322/L494 Workshop Manual: https://bit.ly/2zc58JQ

  14. #11
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    Default Re: Defender Puma Output shaft

    Quote Originally Posted by Orxy View Post
    I thought about that, but the centre ATB won't prevent the output shaft from stripping?
    No it won't but you doing work on the transfer box anyway so might as well upgrade. It did reduce the backlash on mine though.

    The build quailty on the later LT230s was terrible.
    Discovery Sport 2.0i D
    Defender 90 LE Puma 2.2TDCI
    Defender 110 DC Td5 (life partners)
    Discovery 1 200 Tdi Auto

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