fmmv

If its use is just as a dowel, could not a person with a lathe produce something similar, ok not sprung, but maybe loctited into place?

I don't know the correct name but that's the sort of thing for keeping a control knob on a pot on an old fashioned radio or cooker. I (carefully)googled ' control knob spring clip' and some were returned.

True, but one possible solution. I remember dynamos and seems amazing now alternators were a breath of fresh air. The dynamos themselves are quite reliable and easy to fix, the cotrol boxes were cantankerous. Maybe there are solid state controllers these days.

If authentic appearance matters you can get alternators that look like dynamos eg link, dynalites. The dynamos aren't normally too bad, brushes are the usual thing, but those control boxes....

If you have to replace the turrets, I like Gwynn Lewis's- they are open so you can rinse the mud out. And galvanised.

All Land Rover repairs are temporary! They just vary in temporariness. The intermediate shaft is an appalling design, it can wobble about on the O ring varying the gear mesh. I have wondered if it might be possible to fit a welch plug in the casing.

Mine certainly isn't. If you take the plug out there is always some air, by the time the plug is out there is anyway, can't see through the plug so it may have been full. If the heater is working there probably isn't an airlock, that seems on mine to be the first thing to show an airlock.

Not sure how you coulld change the O ring in situ but if you take the box out it's quite easy. There is a tech archive article, I think 'the O ring bodge' or similar.

You should be able to smell which oil it is, EP90 has a distinctive smell. If it is EP90, it's the transfer box, and the layshaft O ring has to be prime suspect.

Yes I too have found plusgas way better than wd40 for freeing up Needs time to work mind. But seems no longer available in 5l cans. Looking at Bulldog Bdx as a replacement.

I like irony too it was a lift pump you were fitting; sounds like the diesel was happy to make it's own way anyway.

I have wondered why the ring gear and diff aren't dowelled together like eg crank and flywheel. They would help if the bolts are stretched momentarily

Is this a Puma pulley?

If you go for a Sykes they do a special adaptor for TD5, and another for 300tdi, as far as I know not usually included in the kits. @Peaklander got a non-Sykes one from Amazon I think, for 300tdi, this one, and that worked for him. You could get the Sykes gauge and specific adaptor quite a bit cheaper than a kit. ( I have been looking into this myself for a while)

Defender 300 tdi has that kind of handbrake, as I think do earlier ones, but there are different versions, with different cables. The parts book is your friend.