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LT230 is off of the defender. Just replaced center pin and thrust washers in center diff. When turning either the front or rear output flanges they take a little more effort to turn than before the rebuild. Exactly how should they feel? Spin freely or should have a level of stiffness? Plus if I...

It does smell a bit bad doesn't it...

The thrust washers are actually completely gone. Disintegrated into a bronze paste. Pins appear ok. I had ordered a new gear set from Ashcroft transmissions plus a HD crosspin and new thrust washers in anticipation of issues with the center diff. Later this afternoon I will install these parts...

Go to the top of the class sir!

Ok... so following on from the above actions to find the cause of the unbearable banging when taking up drive or changing gears I took the transfer box off the 110 earlier this week and got a chance to disassemble it earlier this evening. Took center diff out, removed front tapered roller...

As an update: Input gear back in place and gearbox refilled. When difflock is engaged there is no clunk when taking up drive. Switching back to high or low range brings the clunk back. It is almost impossible to drive smoothly now. So... i guess the center diff has to come out now .

This is also worth trying. I will attempt this later and let you know. Thanks.

I see where you are going with this. I will give this a try and report back. Thanks.

Thanks for responding. I haven't tried this as I hardly use diff lock. What is your theory on this?

2004 Defender 110 (ROW Spec.) 300tdi, R380 Greetings, I have been experiencing a significant clunk while taking up drive and when changing gears for quite a while. There appears to be slack in the drivetrain and takes effort on my part to keep the drive smooth and lurch free. My...

Brilliant! Thanks as always.

Good day, Can anyone advise as to the part number for a clutch slave cylinder for a R380 gearbox? I replaced the seals in the past with a kit from Almakes 4x4 but I suspect it is time to replace the cylinder. 2004 Defender 110 R380 Gearbox 300tdi engine (ROW Spec.) Thanks in advance.

Thank you both for replying. I understand. The FIP pulley can come off but the FIP should remain "locked" in place with the timing pin. In relation to the Cam pulley I assume it can come off without having to worry as unlike the FIP it is actually aligned by marks. So once I line up the...

Fantastic post! Very decent of you to provide the dimensions for the Crank Pulley locking tool as well.

Greetings, 300tdi Defender. I am planning to replace the Cam belt in early April this year. While I am at it I would also like to replace the crankshaft and camshaft oil seals plus the front cover gasket (image attached) which lies between the rear of the front cover and the engine block. What...

You said above that you had the "rear" out but you didn't mention the front. Hence the reason I said don't rule the front diff out. I personally was chasing a loud metallic rattle for almost two years only to find out that the internals of my front diff were in pieces. One sure way to tell...

Don't rule out front diff. If diff is the original type the rattle could be the shaft for the spider gears that has snapped.

15w40 synthetic blend

2004 300tdi engine with 75,000 miles on the clock. Things I did and the order in which they were done: 1. Replaced rover cover gasket and torqued cover down firmly. 2. Replaced inlet/outlet manifold gasket 3. Torqued up oil pressure sensor firmly in place 4. Removed, cleaned, resealed...

This rattling literally drove me crazy for 2 years until now when I currently use a very tacky double-sided tape also squashed in strategic positions as stated above. My aim is to order some window channel in addition to renewing a broken catch assembly. Someone should be around soon with a link...