Defender Transfercase mount tear





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  1. #1
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    Default Transfercase mount tear

    Hi Gents

    The transfer-case mount on my 110 defender has started to tear on both sides of the bolt hole. I have never heard of this happening on a Defender before.

    Im cautious to drive as to not cause more damage.

    I would like to get this welded with some sort of additional support, does anyone know of someone that does decent chassis work.

    Will try and take a picture tonight.
    Pieter Greyling
    ONE LIFE, LIVE IT!
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    -Land Rover Defender 110 Td5
    -BMW F800GS

  2. #2
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    Default Re: Transfercase mount tear

    My 2001 defeder 90 has cracks on both side of the bolt on the driver side transfer case mount.
    I jacked up on the mounting bolt to level the mounting tap and ran a couple of welds over the cracks
    now waiting to see if they reappear - if so I`ll weld in exsta support
    2001 Defender 90 TD5

  3. #3
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    Default Re: Transfercase mount tear

    Quote Originally Posted by phhenning View Post
    My 2001 defeder 90 has cracks on both side of the bolt on the driver side transfer case mount.
    I jacked up on the mounting bolt to level the mounting tap and ran a couple of welds over the cracks
    now waiting to see if they reappear - if so I`ll weld in exsta support
    Does it look similar to this?

    Pieter Greyling
    ONE LIFE, LIVE IT!
    ORRA: Z85
    LROC member:5881

    -Land Rover Defender 110 Td5
    -BMW F800GS

  4. #4
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    Default Re: Transfercase mount tear

    Quote Originally Posted by pjf110 View Post
    Does it look similar to this?

    The cracks started in the corners of the bends due to bad finishing of the corners. You get a "stress riser" where there is a sharp corner or even just a slight nick on the surface. If you do weld the cracks do a bit of preparation and you probably won't have any further damage. Drill a small hole at the end of the crack to prevent it progressing further. A 2mm or 3mm hole will do. "V" the crack with a small grinder on both sides so that you get good penetration of the weld. Blend in edges of the material especially in the corners so that they are nice and smooth. It's a bit of work but worth it in the long run. The finish on many mass produced isn't great and a bit of work before fitting a new one will save you having the same problem once again.
    The humble person makes room for progress; the arrogant person believes they’re already there.
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  6. #5
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    Default Re: Transfercase mount tear

    This crack thing on the defender's seems fairly prevalent from this thread anyway

    Had me going down to check - but all good

    Just one more thing to worry about now

    I think The D3's crankiness is easier to live with

  7. #6
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    Default Re: Transfercase mount tear

    Quote Originally Posted by Paul#25 View Post
    The cracks started in the corners of the bends due to bad finishing of the corners. You get a "stress riser" where there is a sharp corner or even just a slight nick on the surface. If you do weld the cracks do a bit of preparation and you probably won't have any further damage. Drill a small hole at the end of the crack to prevent it progressing further. A 2mm or 3mm hole will do. "V" the crack with a small grinder on both sides so that you get good penetration of the weld. Blend in edges of the material especially in the corners so that they are nice and smooth. It's a bit of work but worth it in the long run. The finish on many mass produced isn't great and a bit of work before fitting a new one will save you having the same problem once again.
    Thanks for the detailed reply. The real problem is there really isn't space to work on top without removing the TC. Also I don't trust my upside down welding skills with a stick welder.

    I will take your methodology to a decent welder(if I can find one) and see what we end up with.
    Pieter Greyling
    ONE LIFE, LIVE IT!
    ORRA: Z85
    LROC member:5881

    -Land Rover Defender 110 Td5
    -BMW F800GS

  8. #7
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    Default Re: Transfercase mount tear

    also heat treat to reduce thermo stresses around and after welding
    Last edited by BarryCH; 2020/07/10 at 02:15 PM.

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  10. #8
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    Default Re: Transfercase mount tear

    that looks identical to myne
    2001 Defender 90 TD5

  11. #9
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    Default Re: Transfercase mount tear

    Build a mount off the vehicle and bolt it on.
    Jakes Louw
    2012 Jeep Sahara Unlimited 3.6 V6
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  12. #10
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    Default Re: Transfercase mount tear

    Quote Originally Posted by pjf110 View Post
    Thanks for the detailed reply. The real problem is there really isn't space to work on top without removing the TC. Also I don't trust my upside down welding skills with a stick welder.

    I will take your methodology to a decent welder(if I can find one) and see what we end up with.
    If you can remove them and bring them to me in Edenvale, then I'll weld them for you.
    The humble person makes room for progress; the arrogant person believes they’re already there.
    2004 Disco 2 Td5
    Suzuki SJ410 (being rebuild)
    VW Touran 2.0Tdi
    Lotus 7 (replica - not a kit)
    Freelance Photographer (part time)
    Member Of: Southern African Freelancers' Association

  13. #11
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    Default Re: Transfercase mount tear

    Quote Originally Posted by Paul#25 View Post
    If you can remove them and bring them to me in Edenvale, then I'll weld them for you.
    Appreciate the offer but the mounts are welded to the chassis from factory.
    Pieter Greyling
    ONE LIFE, LIVE IT!
    ORRA: Z85
    LROC member:5881

    -Land Rover Defender 110 Td5
    -BMW F800GS

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