Series 3 rebuild

piston-return-spring said:

what exactly is broken on the gearbox? nice chassis between

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the linkage for the high box 4 wheel drive is broken inside the casing, the low box works with 4 wheel drive, the lever goes down but doesnt stay down and nothing is happening in the gearbox at all when its pressed, and it is definetly attached on the front of the box ive checked all that, and you can pull it straight back up no matter were the high low lever is, so no doubt something is seized or broken in there, so its another thing for me to learn about!!

is there a common problem with that lever?? a certain thing that generally breaks just so i sort of know what to look for?

thanks
ieuan

remove tin cover and check shaft can move in housing pulling on red knob lever operates pivot working other

not much has happened in the last few days but i did put the front axles back together and its on its wheels for good now



So then i carried on cleaning the gearbox up, just to make it easier to put it in and work on it





So today i bit the bullet and decided it would be easier to work on the box when its fixed on the chassis, so the gearbox and engine are in!!







and then of course the fuel tank



i will be spending all day on it tommorow but i dont think there will be much obvious work because i have to strip the bulkhead and repair a little split so that it can go off for galvanising so it doesnt hold up the project for to long

sorry for the lack of posts this week, its been a very busy week with college open evenings.
Nothing happened on the landy because of that in the week, but i have started to do some work on the gearbox on saturday.
I have changed the gear lever for another second hand one we had with a new o ring, so now i can change gear properly, not with the lever in 3rd and gearbox in 2nd.

I have started to look at the 4 wheel drive problem, but not got very far, ive taken the tin cover off of the front but it doesnt reveal much, am i going to have to take the whole casing off? any help would be appreciated

The rear prop is on with a new UJ, but of course another problem, when trying the hand brake i realised that the whole backplate was moving, so that will be on tommorows job list!!

so there should be some more pics up on sunday night, because i know how much you guys like pics

Its been a bit of a slow week on the landy to be honest, every time i completed something i found another problem, but hey thats land rovers isnt it!!

I have managed to change the shot UJ in the rear prop and have fitted it with new bolts, ive done the ball joints on the steering arm, and have started to play with fixing the gearbox, which is as you can imagine not much fun with a horrible cold in a cold workshop!

Not taken many pics because not been down in the workshop for to long cos of my stinking cold, but here is a few pics anyway.













next is to take the drum off the gearbox and tighten the back plate up,

then take the casing off of the transfer box to fix whatever has gone wrong in there,

and then i can build my new relay to wheel steering arm up with new ball joints and clamps, a nice clean job!!! ,
put the steering relay in

and only then am i going to move on to sorting the engine out, so timing belt, service, tappet clearances and all that boring stuff!

so i will keep you posted with the progress and hopefully i will feel a bit better soon so i can get on with it properly.

Keep up the good work.

And who says all young 'uns sit around playing video games?
Good work young lad!!

Did a bit of tinkering tonight, but still feel properly ill so didnt do to much,

Ive built up the relay to wheel steering arm, cleaned and painted the relay
and then took the hand brake drum off to find that not only the backplate was loose but the expander is also moving around about half an inch each way! so if i sort this out it might mean when its sat with the hand brake on it wont move about 3 feet.

and of course some more pics, (and sorry about the focus, it was a bit cold in the workshop tonight so my hands were a bit shakey!)











so i will carry on tinkering throughout the week and will keep you posted

Nice one, great pics too............

Looking good much respect young man. If you walked in to a job interview and took the details of the rebuild you have done and what was involved most employers would be very impressed, i would employ you.
On the transfer box problem, i am novice myself but i read this thread the other day and thought it might shed some light on your issues, it seems the shafts take some work to free them off from what i have read.
Transfer box problem

Right well sad to say absolutely nothing has happened on the landy during the week, due to school and college open evenings. so i got on with it this weekend but i am at the boring and slow going jobs stage so not a massive amount has been done.

I tightened up the hand brake back plate and then spent 2 hours trying to get the shoes back on!! ... ive decided i dont want to do it again!!





Then i sorted the front prop, new uj in one end and new gaitor and some grease because it was as dry as a bone when i took it apart. (the gaitor kit from paddocks had a jubilee clip that was to small on the wider part of the prop, should of known i suppose!!)



So then i cracked on with getting this annoying gearbox working, i took the front output flange casing off, to find that all is not to bad, i think its just that everything is a bit tight, ive stripped it all down just to make sure and have cleaned it all up, ( this is my idea of hell but it has to be done)











BEFORE:



AND AFTER...................................A WIPE WITH A CLOTH



so ill be putting all the gearbox back together in the week, and front prop on, and then if i get time i plan to put the relay in and then its onto the engine service, so hopefully if all goes well in the next 2 weeks ill have done all the boring stuff and i can get onto bodywork!!

oh, and this wednesday i have off because of the strike so the plan is to take the bulkhead to the galvanisers

so ill keep you posted.

put the gearbox back together yesterday night, and a bit of swearing later it was on and working as it should, really pleased





so took the bulkhead to the galvanisers today, should be back in a couple of weeks, also threw in some rear under floor struts, because i can really

so now i need to think about paint, because once the bulkhead is back i need to paint it straight away, ive looked at a few, i tried dark blue hammerite on some headlight bezels which i had lying around, which i like the colour of but worry it wont last very long, i was thinking some kind of coach paint but dont know were to get it from, as i want to paint it with a brush or roller, but then im still not decided on the colour, (can never make me mind up!!) i looked at painting it a land rover colour, but i only like the bronze green,

so if anyone has any suggestions of were to get it and different colours and some tips i would really appreciate it.

thanks
ieuan

forgot to say, im also looking for a tub, as you may have noticed my current one is a mess, i have got one that i can have which i will probably go for but it needs a floor and the right hand panel needs straightening, so if anyone knows of a better one that is being sold then please let me know

thanks again

You'll need to use a specific primer for gavanised stuff, otherwise ya paint will fall off, honest, it WILL.

mad git said:

You'll need to use a specific primer for gavanised stuff, otherwise ya paint will fall off, honest, it WILL.

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ye we already have the stuff, its a primer that my dad uses to paint the galvanised chassis's, have also used it on the last 2 galvanised bulkheads we have done and put hammerite on top, works really well!
thanks anyway

for coach paint google smith&allen I had some off them last year £30/gallon I seem to remember

ormondstreet said:

for coach paint google smith&allen I had some off them last year £30/gallon I seem to remember

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thanks mate, think im going to get it from there but just got to decide from the huge range of colours!

well sorry to say that nothing has happened to the landy in the last week, had a load of exams this week so i just couldnt, will hopefully be finishing the timing belt tommorow though, with new filters, oil and check the tappet clearances,

so as it was so cold i decided to have a go at things i can do inside, so the headlight bezels on my old wings are bare aluminium, so i wondered what they would look like polished, i have spent about 5 mins on one of them and i think they could look great with some elbow grease



so as usual i will keep you updated

right well at the weekend i had a little go at the timing belt, and so 3 hours later it was going very slow, the classic water pump bolts and all of that, but the cover is off , to find another problem, the front crankshaft oil seal is leaking so that needs to be changed, im waiting for a new one so i will leave the belt on for the moment so that nothing gets moved





i had a few spare hours today so i fitted the relay, just havnt got around to fitting the drop arm to the steering arm, have also started to fir the exhaust, but classic paddock parts because the front pipe has a wrong angle somewere, so i will be seeing if i can sort that,








right so slowly its getting there, hoping that the bulkhead comes back before the xmas hols otherwise it will be after xmas which could be a problem

with the exhaust system, and i know there are gonna be people that say oh dont do that its silly, but i wanted to make it sound a bit more burbly, on the defenders we do, we fit the de-silencer pipe on the front and leave the small silencer on the back, this leaves a nice sounding exhaust note when u hoof it but it isnt stupidly loud and just attention seaking, ive been looking at how to do mine so that it is a bolt onto the intermediate pipe so that if it is a pain i can just bolt the silencer back on, i was just wondering if anyone has ever done anything like this or knows anyone that can help or any products that can be used, (im assuming a straight through is gonna be stupidly loud??)
thanks in advance for any help

so i will keep you posted on the progess

nice build, ive also been playing around with land rovers since i was 13.
on my series 3 200tdi i have only got the disco rear silencer in there and it does sound really nice, but the pipe is also freeflowing and shorter than most so it does help.

i dont know how it would sound with no turbo though cos mines got the turbo and turbos do tend to silence a bit of noise, mine is as you say, really nice sounding when you hoof it but not stupid.