Td5 worn gear in steering box

Hi Everyone,

I haven't been here for a while but my Defender 2005 110 Td5 is getting to an age where things are starting to go wrong! I have had wandering steering, like soft tyres, that the MOT inspector picked up as wear in the steering shaft. Assuming worn UJs, I removed the shaft to find the splined shaft of the steering worm gear is badly worn (see photo). `Obviously, it needs replacing. Has anyone done this? Can it be done with the box in the vehicle? And would it be cheaper to just replace the box?

I've been looking at replacement boxes and wondering where the best place to get one would be? Or perhaps second hand? The second picture is of the lower steering UJ.

I would be tempted to get a refubed/exchange steering box. Mine sprang a leak and I got a replacement from https://www.wearediffs.com/landrover-steering-boxes
A new arm and pin kit adds around £35.

dga3240 said:

Hi Everyone,

I haven't been here for a while but my Defender 2005 110 Td5 is getting to an age where things are starting to go wrong! I have had wandering steering, like soft tyres, that the MOT inspector picked up as wear in the steering shaft. Assuming worn UJs, I removed the shaft to find the splined shaft of the steering worm gear is badly worn (see photo). `Obviously, it needs replacing. Has anyone done this? Can it be done with the box in the vehicle? And would it be cheaper to just replace the box?

I've been looking at replacement boxes and wondering where the best place to get one would be? Or perhaps second hand? The second picture is of the lower steering UJ.
View attachment 248593View attachment 248594 View attachment 248593

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I’m trying to work out how it has worn like that. I can only presume it wasn’t fully located on the splined shaft and I wonder how you were able to steer at all !!

meego said:

I’m trying to work out how it has worn like that. I can only presume it wasn’t fully located on the splined shaft and I wonder how you were able to steer at all !!

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My conclusion also. The UJ was seized on the shaft but slides nicely now. The securing bolt in the UJ slides in a groove parallel to the shaft so if the bolt was not removed, it would not slide the whole way. So someone has had it to bits before!

dga3240 said:

My conclusion also. The UJ was seized on the shaft but slides nicely now. The securing bolt in the UJ slides in a groove parallel to the shaft so if the bolt was not removed, it would not slide the whole way. So someone has had it to bits before!

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Are the splines ok in the UJ ? If they are you could try pushing it fully on and with the bolt located see how the steering is then. It’s still not ideal though as it would only really be located on about 70% of the splines. I don’t think I would be happy with that set up.

miktdish said:

I would be tempted to get a refubed/exchange steering box. Mine sprang a leak and I got a replacement from https://www.wearediffs.com/landrover-steering-boxes
A new arm and pin kit adds around £35.

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That doesn't sound too bad.

meego said:

Are the splines ok in the UJ ? If they are you could try pushing it fully on and with the bolt located see how the steering is then. It’s still not ideal though as it would only really be located on about 70% of the splines. I don’t think I would be happy with that set up.

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I am in the Highlands so will have to do something like that short term anyway. It goes back together this afternoon until I can work out what's best to do!

Although pretty rust covered the splines look ok. Why the splines are machined away at the end of the shaft to the left in the pic I do not know but they are all like that. If the pinch bolt holds the UJ solid on the shaft passing along the groove then good to go.

tottot said:

Although pretty rust covered the splines look ok. Why the splines are machined away at the end of the shaft to the left in the pic I do not know but they are all like that. If the pinch bolt holds the UJ solid on the shaft passing along the groove then good to go.

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My curiosity got the better of me after reading your post, so I went out to the garage and checked a couple of boxes I have. You are indeed correct that the first portion of the splines are machined. No doubt to aid location of the UJ. But I have another box that is fully splined with a flat to locate the bolt. I can’t remember what that off of

How many bolt's in the top cover of your fully splined box ?

tottot said:

How many bolt's in the top cover of your fully splined box ?

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Four. It’s definitely a Defender box. The other one came off my Disco.

Guess it is just different makers. The one on the right allows you to turn the steering column shaft to get steering wheel in the position you want before slipping the UJ on. With the other steering wheel has to be remove unless you are lucky.