Bulkheads

Seaswood · Feb 22, 2023

This is a picture of the bulkhead in 84 110 PU of the wiring loom through to engine Bay Area.
Still in truck, the sills were welded to bulkhead very rusty footwells so on.

4D6D620C-8694-42A9-B205-9EB3EE03A949 by seaswood, on Flickr
This is a picture of the donor bulkhead no through bulkhead passage for wiring loom?
I do not know what model year this was, but it is R hand & R hand bulkheads on this side of the pond are rare. So will this work assuming would need to cut a hole for wiring?
There are other differences hopefully minor, the sheet metal piece under dash fit I will have to drill holes for the top mount. But until I get the original out next to the donor will not know, how well it will work?

2BAFA225-4954-4748-9B2D-107BC9B678E6 by seaswood, on Flickr

miktdish · Feb 23, 2023

Yep, the loom hole is deffo missing .... as are the holes for the gearbox tunnel fixings, very odd ...
Canyou zoom out a bit more ?

dag019 · Feb 23, 2023

miktdish said:
Yep, the loom hole is deffo missing .... as are the holes for the gearbox tunnel fixings, very odd ...
Canyou zoom out a bit more ?

It looks like the gearbox tunnel holes are missing because it has been trimmed to fit a different transmission as it does not look the correct shape and it is not quite straight. It also does not have the main wiring loom hole because it is a td5/ROW spec (rest of world) which used a different wiring loom through the two oval holes higher up. Again you can see the Later TD5 style rubber grommet in the oval hole rather than the older plastic plate with three holes in.

In terms of your question I would have through there will be no issue with carefully measuring and cutting out the wiring holes as it is only a single sheet of tin at that point. More of an issue is likely to be the transmission hole and any other difference in terms of brackets etc. but all are fairly straight forward to rectify. I have just done a bulkhead swap as part of my rebuild (thread) and I had a couple of brackets that needed moving and some additional holes and rivnuts to fit to get everything to fit.

This video from LR Workshop shows what I am talking about with the td5/ROW spec and also goes through the differences in wiring loom.

Seaswood · Feb 23, 2023

Thanks I am hoping to get both bulkheads to a welder friend by summer?
Then determine if saidwelder is willing.
Next up is removing the wiper motor & the wiper assembly see if that will fit.
I believe I have one frozen wiper arm see how long that takes.
Evidently need to make room to access the td5 bulkhead for comparison of that tunnel?

dag019 · Feb 23, 2023

Seaswood said:
Next up is removing the wiper motor & the wiper assembly see if that will fit.

There are two different styles of wiper box which are different sizes/shapes for the hole in the bulkhead required. That is the only difference that I am aware of in terms of the wiper assembly. if you have the larger oval holes in the bulkhead you need the larger later model wiper boxes (which can be fitted to the older rack). If you have the smaller round holes in the bulkhead you need the earlier models wiper boxes which can be fitted to a later model rack. Do not do what had been done to my donor bulkhead (all other parts not he bulkhead itself) and drill large holes in place of the small ones and force the later model rack to fit an earlier bulkhead! This is how I know the wheel boxes are interchangeable as I fitted the earlier model wheel boxes to my later model rack to fit the small holes in my earlier model galv bulkhead that I was fitting.

Seaswood · Feb 23, 2023

What I noticed was the old bulkhead has a hole space for the mechanism that runs from the wiper motor to fit through.
That is directly under upper frame work dash sits on, the newer bulkhead does not.
I will check size of holes tomorrow, wiper motor screws are loose but a wiper is frozen.
Until I free it.

Seaswood · Mar 15, 2023

Well on of the fittings was surely frozen.

1330B6C0-19BA-4285-80C3-2173B02C9E67 by seaswood, on Flickr
That was drilled out.
As you said older style has round holes 84 the replacement has the larger oval holes

1D06ACA1-6864-4BE9-BB29-1EC8E2C04B3A by seaswood, on Flickr
This adds to the list of necessary modifications with transmission tunnel so on

Seaswood · Mar 15, 2023

replacement from the footwell going up transmission cutout 7” original is 6”

D0341799-EF73-4CBD-9A64-CEC5D573F92B by seaswood, on Flickr
All the screw holes along the transmission tunnel were cut off.

E51776D0-B1EA-4504-B0E0-F2E36460802C by seaswood, on Flickr

nobber · Mar 17, 2023

Thats a TD5 bulkhead, they fit, tunnel needs cutting out to the diaphragm shape, wiper mechanism will fit but you have to cut the brackets, a few extra holes here and there and the wiper motor needs fixing, its all doable.

Seaswood · Mar 17, 2023

The wiper hole in bulkhead is much bigger than the small round hole in original earlier, do you use a different mechanism?

The transmission tunnel center bit may need to be shifted over seems.

nobber · Mar 18, 2023

Seaswood said:
The wiper hole in bulkhead is much bigger than the small round hole in original earlier, do you use a different mechanism?

The transmission tunnel center bit may need to be shifted over seems.

From memory I just used big washers, I will have a look later.

Use your original diaphragm to map out the tunnel position on the bulkhead, the part that bolts between the bulkhead and the tunnel bit over the gear box. You can then drill the holes etc, One tip is to weld nuts behind the holes you drill or use rivnuts , it makes disassembly so much easier when changing clutches.

dag019 · Mar 18, 2023

Seaswood said:
This adds to the list of necessary modifications with transmission tunnel so on

Seaswood said:
The wiper hole in bulkhead is much bigger than the small round hole in original earlier, do you use a different mechanism?

I assume you are talking about the hole the spindle goes through from the rack inside to the wiper outside. Do not modify the bulkhead for this just buy the correct spindle as there are two different sorts. (I know it is annoying and additional cost to buy more parts) this way the job is done properly and the expensive bulkhead is not modified for the sake of some cheap wiper parts. The wiper boxes are interchangeable so you do not need the whole wiper rack. I have just done this on my bulkhead replacement and gone from the newer oval wiper boxes on my donee wiper mechanism to the older round ones to fit my bulkhead.

older round (small hole) wiper box: PRC8495
Newer oval (large hole) wiper box: DKU500010

the wiper arms for each is also different but I don’t have the part numbers to hand as I bought them second hand from a spares day.]

nobber · Mar 18, 2023

I just took a look at my wipers, I fitted a washer then an M8 (13mm) nut on the spindle below the wiper arms, Its been like that since 2007 when I fitted the TD5 bulkhead. Its an 85 90 with original wipers. From memory there was one bracket that needed cutting to make the wiper boxes fit on the bulkhead.

Seaswood · Mar 18, 2023

nobber said:
From memory I just used big washers, I will have a look later.

Use your original diaphragm to map out the tunnel position on the bulkhead, the part that bolts between the bulkhead and the tunnel bit over the gear box. You can then drill the holes etc, One tip is to weld nuts behind the holes you drill or use rivnuts , it makes disassembly so much easier when changing clutches.

So instead of welding the tunnel position on bulkhead what I was going to do you say bolt it up to make more room later.
Okay.

Seaswood · Mar 18, 2023

older round (small hole) wiper box: PRC8495
Newer oval (large hole) wiper box: DKU500010

I have up to 1987 & post 1987 fiche that lists prc8495 & rtc4480 mentions difference of pinch bolt or grub screw?
Maybe TD-5 was later.
I will ask next week about the newer oval large hole wiper box.

nobber · Mar 18, 2023

Dont weld the tunnel to the bulkhead, you will never get the bolts in for the gearbox , this is before and after cutting for the tunnel.

nobber · Mar 18, 2023

Modifications to make the wipers and wiper motor fit.

nobber · Mar 18, 2023

Seaswood · Mar 18, 2023

Thank you great.
You cut three holes for the wiper gear shroud, which one worked?

Assume once you get transmission in you put the cutout back in, or are those the holes for the tunnel cover?
I did get the transmission in with stock tunnel.
I was looking at where you cut the hole for wiring through bulkhead.
As soon I will need to start identifying wires before pulling through old bulkhead.

nobber · Mar 19, 2023

Seaswood said:
Thank you great.
You cut three holes for the wiper gear shroud, which one worked?

Assume once you get transmission in you put the cutout back in, or are those the holes for the tunnel cover?
I did get the transmission in with stock tunnel.
I was looking at where you cut the hole for wiring through bulkhead.
As soon I will need to start identifying wires before pulling through old bulkhead.

I drilled three holes for the wipers and cut all of them out to give room and prevent rattling , the holes are for the transmission tunnel, it has to be like this because when changing the clutch you need access to the gearbox bolts, you just have to copy everything on the old bulkhead across to the new bulkhead.

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