200tdi rebuild

thats rusty!

My favourite bit is the big plate which you can see in the first two pics. The metal underneath was virtually none existant.

looks like a poorly done repair, is it ?


someone just slapped a cover up piece over top

Yeah, most of the patches are like that on it, good welding though.

seems a shame then if weldings good not to do the patch properly

Slight update, chassis is all primed up and first coat of topcoat has gone on

keep up and it will be running by winter..

Finished painting now, I'm gonna get started rebuilding the axles now, I would like to have it done before winter so I best get cracking

AlbertDefender90 said:

Finished painting now, I'm gonna get started rebuilding the axles now, I would like to have it done before winter so I best get cracking

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axles is a job i find quite theroputuic

Hi all, just another brief update, fallen behind a little unfortunately. Picked up my front axle from the blasters a the other day, and treated it with fertan just to be sure.



Just finished the treatment today, and fitted the swivel housings. Hopefully I'll finish cleaning up the diff and get the front axle painted tomorrow.

Other than that, I've started sorting out the engine with new timing belt, gaskets etc, and I've finally got some radius arms to suit the new front axle.

Just having a session stripping and cleaning parts. Pulled the transfer box off to replace it and found the output shaft was a mess

Recon/exchange job or is it easy enough to replace?

its not a quick diy job ,ensure your new box has a cross drilled input gear if possible

Ill have to have a look at the box I've got ready. I take it the cross drilled gear it to let oil in then?

Also should there be a nut on the end of the shaft?

yes cross drilled gear allows splines to get oil ,nut is just there for stripping and rebuilding unless its the 2wd version fitted to cars etc,if youd been nearer i could have shown you how to change shaft

Another update, got front axle painted up this weekend, just needs putting back together. Spent forever cleaning all the ancient waxoil off the diff but got there eventually.

Also started tidying up the engine and put some paint on it to get it looking a little better.

Looking good, keep up the steady work.

Just had a mad session cleaning parts ready for painting tomorrow. I'm not sure what is worse to handle, fertan or t wash!

Really hoping to get the front axle on by next week, should be getting a decent bulkhead with a clean td5 dash on Friday so I've got plenty to be on with. Now the weather has cooled down a tad my workshop is much more bearable.

Albert this is looking fantastic, I will keep a close watch on this thread - keep up the hard work!!

Got a slight dilemma, do I paint the axle while its in bits or complete it then paint it?

AlbertDefender90 said:

Got a slight dilemma, do I paint the axle while its in bits or complete it then paint it?

Click to expand...

If it was me I would do it while its in bits, You will be able to do a much more thorough job of it that way.