I ran out of time so never got any further with sorting the 4wd it on the Freelander.

Whilst under tonight with all 4 wheels on the ground, in gear, hand brake on, I could turn the prop shaft round by hand (not easy, but it would turn as I gripped the wide part of the shaft and turned it.)

Am I right that that indicates the splines have gone in the PTU?

I know the general 'fix' for this is a replacement PTU, but before I order one, is it ever possible that just the splined sleeve has worn?

I'm no expert on the PTU -but from what Ive read on here you appear to have diagnosed a failed PTU and it could be due to the splines failing . You can replace just the splined sleeve - there are threads on the very thing.
Others on here can give more information Im sure. Jules

If you are lucky & it is just the splined sleeve worn, then yes, you can just replace the sleeve. If however the splined output shaft on the PTU is worn, then a recon PTU + sleeve will be needed. (Now Sold). 2008 Freelander 2 (Nazca Sand) SE TD4 Auto. Statutory write off & on WOVR for hail damage but still road legal.
171037Km as of 09/05/22
Superchips Bluefin Flash
Nanocom Evo II (also sold)

And I guess the only way to find out is to strip it all down and take it out?

Correct.... (Now Sold). 2008 Freelander 2 (Nazca Sand) SE TD4 Auto. Statutory write off & on WOVR for hail damage but still road legal.
171037Km as of 09/05/22
Superchips Bluefin Flash
Nanocom Evo II (also sold)

Just a suggestion, there is a drain hole in the space that contains the splined sleeve.

Put the front of the car up on axle stands, gearbox in neutral, shove a screwdriver up the drain hole and get two assistants to rotate the front wheels you should feel the sleeve rotate as the gearbox splines rarely fail. At this point grab the propshaft and stop it from turning, if the sleeve still rotates then the PTU or PTU/sleeve splines have failed.

can't test this myself as I no longer have a FL2 and the Disc Sport has a completely different 4x4 system. Tangiers Orange - gone, missing her
Replaced by Ewok what a mistake - now a happy Disco Sport owner

Is that literally just Drain hole? No bung or plug to remove?

I didn't notice a drain hole in that area.

You have to remember that its a few years since I had the pleasure of stripping out the PTU twice (once to diagnose and again a few weekends later to fix), but I do remember being shocked about the hole.

I regularly went wading (still do) and it was obvious that this would allow muddy water to fill the space containing the sleeve. This would wash out any grease and apply a grinding paste to the splines.

If it does allow you to check if the sleeve is rotating then it's got to be worth a try, as I don't remember enjoying stripping out the drive shaft and PTU. Tangiers Orange - gone, missing her
Replaced by Ewok what a mistake - now a happy Disco Sport owner

Yes, it has needed doing for a while but I keep putting it off, partly because we keep needing the vehicle too.

I've got new shocks to replace on the front, along with new droplinks, and will probably get a pair of wishbones whilst I'm there but don't really want to take all that off and now be able to fix the PTU at the same time, so really need it off the road for a week or so to diagnose and get the correct bits.

It just seems from what I've read that everyone just replaces the whole PTU and the sleeve but I've not really read about anyone replacing just the sleeve.

I would have thought that the sleeve would have been the weak point to save everything else from getting destroyed.

Where exactly is the splined sleeve on this diagram?

The splined sleeve isn't numbered, but it's the light section between No1 and No2 in the picture.  Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.

The splined sleeve isn't numbered, but it's the light section between No1 and No2 in the picture.
I've marked it in red for you.


 Hyundai Ioniq 5 Ultimate. The family car.
2009 Rimini Red SE TD4. Gone.
2006 Tonga Green i6 HSE. Gone.
Audi A5 convertible, my daily driver.
1972 Hillman Avenger GT, the project.

The sleeve is definitely not sacrificial.
The PTU splines were completely and utterly destroyed, the sleeve was barely hanging in there. The RH drive shaft wasn't exactly a happy bunny either.





[/img] Tangiers Orange - gone, missing her
Replaced by Ewok what a mistake - now a happy Disco Sport owner

The sleeve has a circlip part way down inside, it might be a good idea to replace this at the same time.




bearing in mind these are the part numbers for the automatic gearbox, manual is subtly different. Tangiers Orange - gone, missing her
Replaced by Ewok what a mistake - now a happy Disco Sport owner

Nodge68 wrote:

The splined sleeve isn't numbered, but it's the light section between No1 and No2 in the picture.