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  #41  
Old October 11th, 2015, 09:03 AM
MonLand
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Loic Fabro
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Quote:
Originally Posted by Jonesy
I will try to get my sorry arse to his place at 8am and get into it.

Figuring 4 hrs out and 4hrs in so hopefully (touch wood) will be driving it at 5pm with an hour for lunch.
So..... Reality time check now?
Start time was 9:30am and finish time was 1am?
That's be 11:30 of work including 2H for lunch and dinner (and whatever else happened under the truck based on the pics posted, there was a lot of that...).
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  #42  
Old October 11th, 2015, 09:27 AM
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Quote:
Originally Posted by MonLand View Post
So..... Reality time check now?
Start time was 9:30am and finish time was 1am?
That's be 11:30 of work including 2H for lunch and dinner (and whatever else happened under the truck based on the pics posted, there was a lot of that...).
Yep - So what was supposed to be an 8hr job, became a little longer. I think the standing around talking about what to do after the gearbox was assessed was a loss of a few hours, but the beer and Pizza was good. But everyone felt like it took too long....I mean at one point we were hoping in Mikes truck for a 4hr Drive to Roberts to pick up his R380 Shorty. Until some cooler heads (Jeff & Grumpy Bill) prevailed and said - naaaah, she'll be right mate, don't worry about circlips

Charles will tell you it was because of all the extra cleaning we had to do, of my dirty truck - or that may just have been him needing the "whaaaaaambulance" .

But I will tell you all it was because of all Mikes farts all afternoon bring tears to our eyes - that boy has some bad seals
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  #43  
Old October 11th, 2015, 01:17 PM
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Yeah, next project is a new rear main seal for mike.

I don't think estimating is our strong suit, but pretty much everything that could go wrong did, and that damn truck was filthy!
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  #44  
Old October 11th, 2015, 03:49 PM
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Originally Posted by cgalpin View Post
Yeah, next project is a new rear main seal for mike.
And don't forget some diff setting up as well .
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  #45  
Old October 11th, 2015, 04:02 PM
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Quote:
Originally Posted by cgalpin View Post
Yeah, next project is a new rear main seal for mike.

I don't think estimating is our strong suit, but pretty much everything that could go wrong did, and that damn truck was filthy!
Or a 200tdi swap . . .
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  #46  
Old October 11th, 2015, 05:02 PM
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Congrats Jonesy! What an epic come from behind WIN! Eff'n impressive how that situation was turned around through pure will.
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  #47  
Old October 11th, 2015, 05:35 PM
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Thanks Clay - and thanks for your time helping in the am...you missed pizza beer and Mike's leaky seal...epic stuff
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  #48  
Old October 11th, 2015, 05:46 PM
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Steps

Ok - Figured I would post up...

1. CLEAN Vehicle underneath, all nooks and crannies - with a toothbrush if Galpin is involved
2. Crossmember comes out
3. Exhaust comes off
4. Disconnect driveshafts at LT230 - not at Diffs
4. Disconnect LT230 linkages and wiring - sorta depends on vehicle - but Defender ROW have one wire for diff lock
5. Disconnect hand brake cable - take off the cable, not the bracketry (mistake we made)
6. Remove PTO cover (round cover) from LT230 and remove input gear - should pull out easy - inspect bearings & teeth - ensure all looks good
7. Unbolt LT230 and lower - a few niggly ones, but not too bad - only about a 70lb lump, so can be handled singly
8. Unbolt LT77 mounts and ring bolts to engine with it supported by trans jack - keep a jack on/under engine - it helps with removal.
9. undo Clutch cover and take off
10. remove clutch plate
11. unbolt flywheel (if that is hard then rebolt the cover and use it to beat on and lever the flywheel out - it can be sticky (assuming you are replacing the cover of course)
12. Inspect the main seal - leaks? Replace - no leaks - leave it
13. Take off the motor mount brackets from the frame - easier to reposition everything

Replace all parts with new ones in opposite order.

Note when reassembling the gearbox and TCase - put them together on the ground and ensure serviceability, set up linkage etc to ensure it all works. Then either take off the TC or if you feel tough and have enough hands put them both up together.

It think I got everything - others may post up corrections - additions
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  #49  
Old October 11th, 2015, 07:00 PM
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You guys are awesome.

Thanks for sharing the details of the project, well, most of them anyway
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