'Big Blue' Td5 Double Cab

New addition, 2003 double cab




Very tidy underneath as well 4 new bfg ko2s on the way, cleaned the MAF, MAP and AAP sensors today and the airbox. Needs an engine degrease, slight leak on the rocker gasket. Bit of play on the steering, the box is damp round the drop arm but its not using any fluid.
Clunks a bit when you take up drive, only when you rush the clutch or gearchange.
Link to a video showing it all over and I've tried to show the backlash on the rear prop and play in uj's and 1 of the halfshafts.



If anyone could watch and point me in right direction that'd be great I'm thinking new halfshafts and uj's.

I'll keep updating as I do the jobs, got a few little additions planned like cubby box and swing away spare wheel carrier also locking metal lid for pick up bed. I need to carry max 4 bikes on it somehow

XEngineering pedal box on the way, got a crook lock on steering wheel for now but I'll still use it as well. Tracker fitted as well also installing a post on the driveway.

I'll have 2 tyres available if anyone wants them, details in video

Lovely! Glad you got one and made the right choice haha

My boot lid was from NJIAliuminium pricey but the quality is good, bit of a dick to fit but it is useful and secure.

bankz5152 said:

Lovely! Glad you got one and made the right choice haha

My boot lid was from NJIAliuminium pricey but the quality is good, bit of a dick to fit but it is useful and secure.

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Cheers mate!

Yeah I've been looking at those, look the best option but I'll be saving for a bit
Gonna keep an eye out at the shows and autojumbles as well, ya never know.

Any thought on transmission backlash/play?

1988smithy said:

Cheers mate!

Yeah I've been looking at those, look the best option but I'll be saving for a bit
Gonna keep an eye out at the shows and autojumbles as well, ya never know.

Any thought on transmission backlash/play?

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Prop rotational play looks about normal.

UJs will last but have spares on hand for when it gets worse.

Pull the shaft out and check if its the flange it shaft. Got Britpart shafts on mine and theyve been fine last couple years.

On the doors id wanna get those looked at soon, if it gets much worse it geta very pricey! Recently had all my doors welded up for £750

bankz5152 said:

Prop rotational play looks about normal.

UJs will last but have spares on hand for when it gets worse.

Pull the shaft out and check if its the flange it shaft. Got Britpart shafts on mine and theyve been fine last couple years.

On the doors id wanna get those looked at soon, if it gets much worse it geta very pricey! Recently had all my doors welded up for £750

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Sound cheers

Think I'll just replace shafts and flanges if I've got it apart anyway. Uj's are cheap enough so I'll just do em in the next few weeks.
R.e doors, is it grind out the crack and weld up?

Debating wether to go decat front pipe and straight thru middle or leave the centre box on for refinement at mway speeds

Techno trimmed cubby box to match seats ordered from paddocks today £43. The difference in parts availability and price to the disco 2 is a nice surprise. Also it's not as agricultural to drive as I thought it'd be compared to the disco.

Looking at replacement wing top grille for heater box. I've got a hazelnut tree next to my drive so I want to keep the ****e out. Either snow cowl or one of those rdx jobbies with the hooded grilles

1988smithy said:

Techno trimmed cubby box to match seats ordered from paddocks today £43. The difference in parts availability and price to the disco 2 is a nice surprise. Also it's not as agricultural to drive as I thought it'd be compared to the disco.

Looking at replacement wing top grille for heater box. I've got a hazelnut tree next to my drive so I want to keep the ****e out. Either snow cowl or one of those rdx jobbies with the hooded grilles

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Snow cowl is a great addition. Good to hear you enjoy driving it

See if Allisport still do their "bullet" mid box is a lovely mix. Quiet when cruising but a real bark when you floor it, best of both worlds! I would de-cat it as well, turbo will spool up a touch faster.

bankz5152 said:

Snow cowl is a great addition. Good to hear you enjoy driving it

See if Allisport still do their "bullet" mid box is a lovely mix. Quiet when cruising but a real bark when you floor it, best of both worlds! I would de-cat it as well, turbo will spool up a touch faster.

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Yeah it's getting all that and a stage 1 once I've sorted the slack in drivetrain. Ill look into that allisport box, cheers. Possibly intercooler and stage 2 instead if I've got the funds and am happy with how it's running. No point having the extra power/torque if my drivetrain gonna strip its ****
There's an item on eBay, £185 for mild steel decat downpipe, straight thru centre pipe, egr delete kit and pipercross air filter which I think is reasonable*. All in due course though hoping the prop splines are good id rather just do uj's than fork out for whole prop

*feckin cheap as chips compared to allisport

Beware of some of the cheaper decats and straight thrus as they tend to be a smaller diameter. I know the TF one is 2.50 instead of 3"

Intercooler wise Allisport is an excellent choice if you have the cash if not the Britpart one, believe it or not, is half decent. I had it on my 90 for a couple years and worked well. Apparently its a rebranded Serck! Though unproven.

Who you planning to map it?

bankz5152 said:

Beware of some of the cheaper decats and straight thrus as they tend to be a smaller diameter. I know the TF one is 2.50 instead of 3"

Intercooler wise Allisport is an excellent choice if you have the cash if not the Britpart one, believe it or not, is half decent. I had it on my 90 for a couple years and worked well. Apparently its a rebranded Serck! Though unproven.

Who you planning to map it?

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I think 2.5" would be ok with a stage 1 but if I go stage 2 I'd want the 3" wouldn't I? I've got to consider the noise at motorway speeds as well, we'll be using the defender for camping and holidays all over so has to be as comfortable as you'd expect

I was going to look at storm tuning or dynachip for the map or even get it done by alive or BAS at 1 of the shows next year, they tend to do a discount at shows don't they? Remap on my disco was by a quantum tuning franchise, it was fine and didn't smoke at all but id like this done by a company focused on landys

That's the thing with britpart isn't it, it's all a bit if a lottery. A chap on here the other day said their disco 2 standard shocks were crap but I had them fitted 2 years to mine they were great. Luck of the draw

The thing I do like about the allisport decat pipe is they do the 1 with the cat shell so at least it looks like it's got a cat. My MOT mateys getting on a bit now, he won't be doing it forever

1988smithy said:

I think 2.5" would be ok with a stage 1 but if I go stage 2 I'd want the 3" wouldn't I? I've got to consider the noise at motorway speeds as well, we'll be using the defender for camping and holidays all over so has to be as comfortable as you'd expect

I was going to look at storm tuning or dynachip for the map or even get it done by alive or BAS at 1 of the shows next year, they tend to do a discount at shows don't they? Remap on my disco was by a quantum tuning franchise, it was fine and didn't smoke at all but id like this done by a company focused on landys

That's the thing with britpart isn't it, it's all a bit if a lottery. A chap on here the other day said their disco 2 standard shocks were crap but I had them fitted 2 years to mine they were great. Luck of the draw

The thing I do like about the allisport decat pipe is they do the 1 with the cat shell so at least it looks like it's got a cat. My MOT mateys getting on a bit now, he won't be doing it forever

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Buy cheap buy twice as they say. I did buy a cheap decat, regretted it the second it arrived and bought a quality mild steel one, which i also regretted and whished id gone full Allisport.

Storm are run by old JE Enginering folks afaik so rather good but without the supreme price tag. Couple mates have Storm maps and very happy.

I use mine daily, up until recently was doing 80 - 100m a day thats with a mild steel decat and the allisport mid box. Perfectly quiet till about 90mph then its a tad noisy lol

Ive kept my Cat in the garage just incase, doesnt take long to swap.

bankz5152 said:

Buy cheap buy twice as they say. I did buy a cheap decat, regretted it the second it arrived and bought a quality mild steel one, which i also regretted and whished id gone full Allisport.

Storm are run by old JE Enginering folks afaik so rather good but without the supreme price tag. Couple mates have Storm maps and very happy.

I use mine daily, up until recently was doing 80 - 100m a day thats with a mild steel decat and the allisport mid box. Perfectly quiet till about 90mph then its a tad noisy lol

Ive kept my Cat in the garage just incase, doesnt take long to swap.

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I'm thinking standard kind of decat and leaning towards allisport bullet mid section then going on what you've said r.e motorway speeds , stage 1 maps gonna do me I think, just improve driveability and get the turbo kicking in sooner. I don't need anything mental I've got 1 series m sport when I want to cane it

Storm tuning do sound good don't they, lots of positive reviews about.

Can't wait to start fettling, get some pics going on here

Tyres just turned up, a day early. Nice surprise after a night shift! Bed can wait I'm getting these shoes fitted now

What size did you go for out of interest? Planning on replacing mine with KO2 and probably going to go with 265/75/16.

G-P said:

What size did you go for out of interest? Planning on replacing mine with KO2 and probably going to go with 265/75/16.

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I went 235/85 r16 mate. Bit skinny for some but I don't do anything more than greenlane type stuff and at the shows and I understand that was a factory option size

KO2s are great, performed really well in the recent snow on my disco 2 but as you'd expect they're not fantastic in mud but I never had any problems doing standard stuff with them

Can't wait for the blue rinse to wear off it looks ****e



Great looking tyres though and live up to the hype imo


I've got 1x general grabber at2 part worn available for free to whoever wants to collect. I'm in the West midlands p.m for details.
Approx 4-6mm tread, details in thumbnails

Cubby box fitted.

Was never going to use the centre seat, only the kids would fit in it and it didn't have a belt

XEngineering pedal came yesterday so I'll try and fit that before work tonight.

Rear halfshafts, flanges, seals and circlips ordered. I'm getting new flange bolts as well and loctite. Anything I've missed? I'm doing 1 side at a time because the diff oils been done recently with receipt to prove and I've got a litre spare to top it up

Just done EGR delete before I go to work, rear halfshafts/flanges/bolts arrived today so should be doing that over the weekend. Got some slabs to lay in the garden first though, if i dont do it this weekend she'll have my b*llocks

If anyone else is going to do this don't forget to block the 2 vacuum hoses, best done at the manifold/pump thing.


Little dash mascot off my eldest

Coming along well!

bankz5152 said:

Coming along well!

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Cheers mate, nice running project I think

Can't stop smiling when I'm driving it, it's such a laugh and everyone looks at it, it's exactly what imagined, wish I'd had 1 sooner