Symptoms
Perforated outriggers, flaking rear crossmember, failed inspection.
The fix, step by step
- Cut out rotten outriggers or crossmember sections and weld in new ones, then treat the inside of the frame.
- If the rot is widespread, a galvanised chassis swap is often the better answer.
Tools & part numbers
- Welder, grinder, cavity wax
- replacement outriggers and crossmember
Where to buy the parts
Defender chassis outriggers and crossmembersRovers North ↗Amazon ↗
Hunting a used or discontinued part? Search eBay Motors for Land Rover 90 / 110 / Defender parts →
Rated for a competent home mechanic with a decent tool kit. Confirm torque figures, fluids and procedures against the factory service manual for your VIN, support the truck on stands rather than a jack, and work at your own risk (disclaimer). Some parts links are affiliate links, which pay us a small commission at no cost to you.