Southern Africa trip Jan-Apr 2023 - mechanical problems

This is a factual video about mechanical problems (specifically a clutch failure) encountered en route. It goes into the underlying reasons and how the problem was fixed. Comments are made about the standard of the local mechanics who worked on this.

[@fransubaru]

Lot's of experience. Thanks for sharing!!

[@KaizuoSilva]

ooh i like this kind of video im subscribbling now 👍🏼

[@davejules4103]

Hi Bill Agree about your comments about British 4x4 in Windhoek. He used to store and service our Land Rover. John is a good guy. He has some good stories to tell also.

[@glentomkins8044]

Sorry to hear about these issues. Wherever you travel in remote areas, bush mechanics can be a very mixed blessing. They get your vehicle running again, but sometimes that's about all you can say for them. I'm glad you're back on the road.

[@mobba-ne4he]

Thank you for sharing! Even Toyota's have problems! I know of 2 Toyota Prados on recent trips that ran into trouble on Africa overland trips and in both cases, a lot of time and money spent on the road, it is what it is.

[@defendermodsandtravels]

Yes and friends we met en route broke the back (i.e. the chassis longitudinal) of their Hilux on the corrugations. The wheelbase is longer and the chassis member less deep than on a Defender 90.

[@stuartdenty3163]

Very useful, thank you Bill.

[@darkgreen68]

Definitely fun to watch. Thank you for sharing.

[@davidbrodie5044]

Very interesting content, thank you for sharing your experience and I hope things go well when you resume your trip.

[@adelarsen9776]

A few comments : 1) There is a wide chasm between a tradesman and a craftsman. 2) Always use the right tool for the job. Pliers and vice grips are the tools of backyard butchers. 3) Buy once and buy right. Quality tools are cheaper in the long run. Poor man buys twice. 4) Bore scopes in Africa are different to the ones I have.... wow. 5) Every weld is an engineering failure. Some geeza from England once told me that. :-)

[@defendermodsandtravels]

Point 5: every unnecessary weld is an engineering failure, particularly if working on a fixed price contract. Your profit lies in having an economic design with optimised welds.

[@adelarsen9776]

@@defendermodsandtravels Agree. I enjoyed the video. Thanks :-)

[@damienkeygan1735]

Very interesting to hear how one event lead to another etc, and glad you were able to identify and overcome the issues to continue your journey

[@defendermodsandtravels]

This a really important point you make. When you are on a big trip and something goes wrong things start to unravel and go downhill rapidly. You have to sort out any problems at the earliest opportunity.

[@phillsmith4060]

Morning Bill! I`ve recently come across your videos, and will be making my way through all of them. A mass of very useful material. But a very mundane matter. Aiming to take my 110 to Turkey later this year, and East of there next year. I have so far drawn a blank on insurance. I'd be very interested in your experience in this area...

[@defendermodsandtravels]

I drove through to Turkey a few years back and was able to get a Green Card from my UK insurer for all countries along the way, as I recall it.

[@overlandingwolf]

L.O.F - I have had the power spec clutch fitted for almost 2 years - I drive a 90 Wolf, 300TDI and tow an expedition Sankey behind her for hours on end - has never let me down and Luke the owner will answer queries on the clutch himself and offers warrantied replacements should it go wrong. I don't think you can beat them! - Great company!

[@defendermodsandtravels]

That's a good recommendation thanks. I am already in contact with Luke trying to sort out what spigot bush I should be using (Daihatsu engine to R380 gearbox). The current bush looked a bit manky when we changed the clutch and I have a feeling I should take a spare back with me when I return.

[@453421abcdefg12345]

@@defendermodsandtravels:- I have also used L,O,F, and found Luke to be very helpful in getting clutch and brake parts to me in Southern France. Chris B.

[@seeharvester]

As to road corrugations, or 'washboard roads' as we call them here in the States, I find that if I drive on the wrong side of the road they seem to be smoother. I'm not sure why that would be; perhaps it's my imagination. Of course it's difficult if there is a high volume of oncoming traffic. :)

[@defendermodsandtravels]

Yup one tries everything to try and it make it better. You feel good because at least you're doing something but I'm not sure it makes much difference.

[@carltonr3417]

Very interesting the issues had with shoddy mechanics butchering things. It’s a shame such an excellent vehicle had to be subjected to that. On another note, if you’re contemplating swapping the motor in the future, have you considered converting it to a 300tdi to match up with your r380? Might eliminate some problems with it being a hybrid and the adapter plate problems. Parts availability would probably be better for a 300tdi. I realise it’s probably not feasible cost wise as these things are never as simple and cheap as it first seems but it would be interesting to go through pros and cons to a swap or sticking with the current setup. Thanks for videos and updates!

[@defendermodsandtravels]

I think constantly about this. The 300Tdi is an excellent motor (I have one in my Disco), more powerful and readily available BUT I have gone so far down the route of integrating the Daihatsu that it'd be a step backwards to change it now. For example, the excellent charging arrangement I have would have to go or be adapted to the new engine and The Daihatsu has a legendary reputation for reliability. For example, the engine has overheated a couple of times over the years and has shrugged it off. The Tdi, with its Al cylinder head, can't take that treatment. Given that I have a spare Daihatsu engine in the garage it'd be easier now just to do a straight swap. I'd take the opportunity to do some tidying up at the back of the engine bay, which I simply can't reach with the engine in place. Thanks for the question.

[@graham-martin5847]

the high low mistake is easily made as i did it once myself not thinking they simply put the clamp that goes onto the teeth of the selector about 45 degrees out easily done

[@oldbritishmetal]

Great advice Bill, as always. One part that I always carry is a clutch slave cylinder. Even though I use Delphi parts and change the fluid annually, these only seem to last for a few years before failing. I'm starting to wonder if there is some incompatibility between DOT4 and the seals. Perhaps DOT5 silicon fluid is the solution?

[@erictyrrell3560]

DOT 5 requires a total system rebuild and compatible seals. DOT 5.1 may be compatible with existing systems. I'd suggest trying TRW components. They've made improvements over the original designs.

[@defendermodsandtravels]

I carry a slave cylinder repair kit under the mistaken assumption that the body would never get damaged.

[@craigbutler623]

Did you and your rover ever make it home? Havent seen an update in some time, hope all is well!

[@angusabbott5615]

If you with LOF ,they have a wire clip for the push for and another for the bearing , I don't think they sell them separately, I always use some thin cable ties to "help" stop the push rod clip failing when the slave cylinder is withdrawn at a later date

[@defendermodsandtravels]

Without the clip it's obviously difficult to hold the pushrod in place whilst fitting the slave cylinder. What did I do? I used the rubber shroud from the old slave cylinder to wedge the pushrod in place. It worked a treat. The next mechanic who works on this will be bemused to see two rubber shrouds.

[@garypoulton7311]

This happened to my valeo clutch, many years ago, it had only done 30.000 miles, I spoke to a specialist, they said they had never changed a Valeo because it was worn out, but because they exploded like ours. I fitted a Borg beck clutch, it had twice as many riivets

[@defendermodsandtravels]

I hadn't really thought too much about the clutch before but it seems that I have touched on a hot potato here. I note that Ashcroft Transmissions and the two local LR workshops here sell Valeo clutches which I assumed was a mark of approval. My last clutch was a Delphi - it was taken out after 80,000 km when we did an engine swap and it appears to be as new. This will now become my emergency spare. It sounds as if I definitely need to think about buying a true heavy duty unit.

[@453421abcdefg12345]

Very interesting! The clutch slave on my TD5 Defender was an unbelievably difficult job, with a multitude of spanner sizes and extremely difficult access to hidden fixings, I was very worried about the clutch pushrod dropping into the bellhousing as yours did, but as mine was last assembled at the factory they obviously fitted the retaining clip, but it was a long and frustrating job, how did you recover the pushrod in the end? I could not see reference to that on the video. Chris B.

[@defendermodsandtravels]

Once I managed to remove the slave cylinder I had much better access. I used a small magnet on a wire to fish it out. If I can find a really small magnetic recovery tool I'll carry that in future.

[@453421abcdefg12345]

@@defendermodsandtravels Glad you were able to recover it without a gearbox out job! It was one aspect of a clutch slave cylinder change that I dreaded, I bought some of the very small "super magnets" with a hole through them, and attached one to a length of welding wire, it has helped me out on a number of jobs, especially when a small part disappears under the bench! Stay safe! Chris B.

[@lukesmith4882]

Out of all the overlanding or expedition channels yours is the most sensible by far. I have been driving land rovers daily for years (just for day to day use not expeditions) and with a sensible approach they are very reliable and robust.

[@mk109siii9]

I had a very similar clutch failure on a 300Tdi 110 just over a year ago. The friction material was good, I drive gently and don't tow much (under 1,000kg when I do) , but the centre of the clutch tore out, it was supposed to be a H/D 130 clutch. Maybe the culprit is not so much the missing bolt, as poor manufacturing.

[@williamcutler5472]

Hi @defendermodsandtravels Have you thought about fitting your defender with a 300tdi engine? If converted properly it would be more reliable, easier to work on and easier to find parts for in the long run. The only problem I can see is that most 300tdi engines are worn out by now! Another thought, I have a defender 110 with a bmw m57 engine fitted. We have done some big trips in it and it has been very reliable.

[@defendermodsandtravels]

See my reply to Carlton R who made the same suggestion. I would also say that this particular bolt hasn't come loose in more than 100,000 km although its sister on the other side did. I knew that it was a risk but was postponing taking any action until I was doing other work on the engine or gearbox. Yes it was shortsighted.

[@williamcutler5472]

@@defendermodsandtravels I thought it might be an avenue worth exploring but breakdowns happen and can't always be helped what ever the vehicle/engine. Keep up the great content, me and my brother are both fans of the channel!

[@reddemon1923]

oh man, it must have been gut wrenching to see them work on you Defender like that! One of my biggest fears is having no choice but to let someone work on my 4x4 and do this to it. Would you have been able to just pay for the use of tools and space to do the work yourself? and just tell them where to stand and what to hold?

[@erictyrrell3560]

Have you tried thread locker on that troublesome bolt?

[@defendermodsandtravels]

I have tried Nylocs, lock nuts, thread locker and all combinations. Eventually it works loose. Same with the starter motor bolts. The only thing which works is a castle nut.

[@barnbuilds7833]

I have an ex mod defender 110 I’m quietly wondering about overlanding with. Can I ask how you find driving a nato green landy about? Do you find yourself getting into any extra “human” trouble?

[@defendermodsandtravels]

No probs whatsoever but I don't visit war zones.

[@hhhc364]

are you still in South Africa?

[@defendermodsandtravels]

Nope. I am in Borneo but the Defender is in Cape Town.

[@hhhc364]

@@defendermodsandtravels nice, where do you store it? we are an hour away on a farm, next week we are traveling back down to South Africa from Tanzania is my Series 3

[@jamesprosser6766]

Hi Bill, can I offer you the free use of my ramp and overhead crane when you are back from your travels?

[@defendermodsandtravels]

Very kind offer, thank you so much. Happily I am well equipped with a pit and a gantry. Only problem is the assembly of the gantry which weighs about 50% of the engine. BTW where are you based?

[@jamesprosser6766]

@@defendermodsandtravels I m based near to Manningtree, I think you are not too far away.

[@defendermodsandtravels]

@@jamesprosser6766 Yup I go past there on my way to London. I am south of Beccles. Meet up and have a beer someday if you'd like to.

[@jamesprosser6766]

@@defendermodsandtravels Sounds great! Would be great to meet you,.

[@defendermodsandtravels]

@@jamesprosser6766 Make contact with me at [e-mail] and we can sort something out.

[@R_ovrlnd]

guess you going to replace all the main bolts washers with nord locks

[@defendermodsandtravels]

I don't need to go through the vehicle from front to back replacing all of them. There are just a few attached to the engine which try to shake loose and lock nuts are good provided you can tension them properly. This one slipped through the net and that was my fault.

[@R_ovrlnd]

@Defender mods and travels yes I understand that , but replacing all the bellhousing washers with nordlock washers would be beneficial, I don't know if you did some research regarding nordlock washers? They are used predominantly in the aerospace and power generation ( wind turbine) , so basically you don't need to safety wire the bolts if you are using nordlocks

[@defendermodsandtravels]

@@R_ovrlnd To the best of my knowledge they aren't used in oil & gas nor marine (my fields) so I am not very familiar with them. I found their website today and I will look more closely now. My bellhousing gives no problems for some reason. The studs into the adapter ring have threadlock and there are double nuts at the other end. Double nuts are generally v secure provided you can get 2 spanners on and nip the nuts tight against each other. If you don't have good access to tighten them they aren't very secure.

[@R_ovrlnd]

@Defender mods and travels that's the thing is space , I actually only find your video yesterday. If bolts can't be properly torqued then they are pretty useless . But I would like to hear your insights on nordlocks after you have done some research on them , they are a bit more expensive than normal washers but truly worth the moneg . so I have been watching some of your videos the Namibia ones , j have just returned from Windhoek a few weeks ago

[@defendermodsandtravels]

@@R_ovrlnd Where you from?

[@Auxbeam]

Hi Do you need some great lighting for your car to help you better driving, off-road? We're the pro auto lighting company for nearly 20 year and we're looking for sponsorship!

[@defendermodsandtravels]

Hi thanks for the suggestion. One of the golden rules of overlanding is to try to avoid driving at night esp. off road. A fancy lighting system would be wasted on me :-) I did once break this rule and nearly lost the vehicle. Never again.

[@StellarBlue-fs1jr]

Hello Bill Adrift on an ocean full of YT nonsense I washed up on your little island of common sense ! I have not yet watched all of your videos but I am curious as to why/how you decided upon a SWB Land Rover for your travels as opposed to the preferred LWB.

[@defendermodsandtravels]

Watch my "General Walkaround" video. All is explained there.