Thread: 2012 Defender drive failure 25,000ks

I've been investigating probable cause, in case my dealer doesn't. I'm worried the problem might be more wide spread and the dealer doesn't want to spend the time to be thorough. They seem very rushed, and I have not heard confidence from others in their work.

Not really having a clue, I have enlisted the research powers of YouTube and now wonder if the worn splines could be a result of excessive backlash due to slack in the lt230, and therefore the transfer case is the real cause?

Am I way off base here, if so, I blame YouTube! Just finding it hard to accept a simple shaft could fail at 25,000km of modest and considerate driving.

the failure of this item at those km and considerate use is purely a materials issue. i would say the new one will be fine.

the little duratorq engine doesn't have enough torque to twist out those splines, never will.

i would say having seen this item that 800Nm would even be ok


don't under any circumstances accept blame for its failure


jc

Takes the shine off a new car doesn't it.

Have a read of this thread.

Defender2 - View topic - Lost all drive...

Found these pics online. Thanks to NunoMathiotte at Area4x4!

Originally Posted by Psimpson7

Have a read of this thread.

Defender2 - View topic - Lost all drive...

Would be interesting to find out if there is a greasable unit. A dry spline doesn't sound very professional at all. Another job for the weekend

Is that a 2piece shaft just so they can fit a tensioning bolt up the first section?

That is what it looks like Dougal.

Those 2 pics show that there is lot of fretting corrosion (the rust like appearance) happening, that no doubt leads to the failure of the splines. Fretting corrosion is caused by relative movement between mating parts.

The issue is best solved by preventing the relative movement, e.g. interference fit (more complicated, but better engineering), or use a one piece spud shaft and a long draw bolt.

Lubrication is a band aid to treat the symptom, and it looks like there is no oil in that section to provide ongoing lubrication, after assembly.

Land Rover had similar problems with the LT230 input splines, and IIRC, tried grease during assembly, but only succeeded in creating greasy fretting corrosion. They created the same problem with drive flanges on half shafts when they dropped oil lubrication of wheel bearings in favour of grease.