Improved intermediate shaft (set) for Defender TD4 - reinforced

Improved intermediate shaft Defender - ENGAGE4X4 set in reinforced version.

The Land Rover Defender TD4 has been equipped with a new engine and a new six speed gearbox from Getrag MT82 since 2007. However, since this gearbox was developed for the Ford Transit, it does not fit the Land Rover LT230 transfer case. To connect the Getrag gearbox with the Land Rover Defender transferbox, the manufacturer has developed a so-called Defender TD4 intermediate shaft in a housing instead of a cardan shaft connection to connect both gearboxes. In the first TD4 models this problem was not so present. Approximately in 2010 the part numbers of the flange were replaced. We assume there was a manufacturer change here.

The built-in weak point of the Defender from factory ENGAGE4X4 improved intermediate shaft

The flange of the Defender TD4 intermediate shaft is in a cast aluminum housing and was installed dry from the factory. The proximity to the exhaust pipe and thus constant temperature changes allows condensation to form in the splines and the intermediate housing. The gearing begins to corrode over time. The corrosion dust and load change impacts do the rest. The gearing steadily reduces. We have had vehicles with just about 18,000 km in our shop that have stopped at absolute wear. Failure of the Defender TD4 intermediate shaft means total loss of mobility. This is absolutely unfavorable for expedition vehicles traveling to remote regions in Africa, Asia, or Russia.

The possible solutions for the problem of the Defender TD4 intermediate shaft

There have been a few attempts to solve the problem, but all have been less than fruitful. Land Rover issued a circular instructing the dealers to use a special grease on the TD4 intermediate shaft, but this was not the solution in our opinion, some vehicles still had this problem several times. There was still the approach to lubricate the shaft with a kind of oil connection, here was not considered however. One builds in another weak point, an additional oil seal with the possibility for an additional oil loss. There are also cases that the shaft is broken under extreme loads, as it is also a material problem.

The ENGAGE4X4 solution for the Defender TD4 transmission shaft

For years we have spared no expense and effort to have a reinforced transmission shaft and flange manufactured in Germany. Together with info from Getrag we were able to determine the exact data of the gearing and paid high tooling costs and developed a flange from S155 (300 M) and a TD4 gear shaft also from S155 (300M). The material S155 corresponds to the common American designation 300M. The material has a load capacity of 1800 to 2000Nm / mm². It is the strongest material that can be used in drive technology. Special properties are high flexibility and very good corrosion resistance. Not enough, we have also thought about the sealing of our shaft and have a special heat-reducing seal manufactured, which ensures a 100% tightness. The shaft is also mounted for safety with an assembly paste. The special sleeve is then shrunk on. There are no more problems. We give 3 years warranty.

Information

• Gear shaft with OE part number TUD500020 in reinforced version from S155
• Gearbox shaft flange with OE LR030054 in reinforced version from S155
• Special reduced sealing sleeve with sealing glue
• Made in Germany
• 3 years warranty