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  #41  
Old June 29th, 2009, 09:01 AM
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Charles Galpin
'94 D90 ST, '63 SeriesIIA
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1. Yes it also welds on - it just has shorter "legs" that overlap your frame rails. If you fram is good all the way to the cross member then you can get one without extensions. Pictures would help to confirm your assumptions though.

2. There are holes in the cross member and the NAS bumper has tubes that go into those holes. If you look behind the cross member you'll see a large bolt facing rearward and that screws into the bumper tubes.

Check out my site for pictures of the rear crossmember in various states

http://lhsw.com/gallery/janey_rear_cross_member
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  #42  
Old June 12th, 2011, 12:55 PM
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Carl Jonsson
1995 NAS D90 #219
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I drilled through my rear crossmember to mount bumperettes only to discover that it was paper thin in at least one area. Looks like it has rusted out from the inside. I have read up on the replacement procedure but I would like to know what differs between a ROW and NAS when it comes to replacing the rear crossmember. Is it necessary to drop the tank?

Also is it possible to get a galvanized rear crossmember with extensions? The galvanized versions I have seen does not appear complete.
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  #43  
Old June 12th, 2011, 01:12 PM
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Charles Galpin
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Yes you have to drop the tank. Certainly no way around that.

Don't confuse the tank mounts with the extensions. The tank mounts are the NAS specific bits, although one of the UK guys recently said they are the same on a TD5 so perhaps someone needs to call Richards and ask for those instead of NAS tank cradle parts.

If your tank cradle is sound and the frame is solid to the rear cross member (they usually are) you can get away with a standard rear cross member and fitting kit. Getting extensions just complicates the issue imo since you then have to cut the nas cradles off and add them back on.

That said, after having done both a ROW and NAS replacement, the next one I do is going to be home made out of thicker box steel and integrate a 2" receiver and bumperettes right into it. It will look just as good and never fail again.
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  #44  
Old June 12th, 2011, 04:22 PM
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Carl Jonsson
1995 NAS D90 #219
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Thanks for info, Charles.

Next question. I am planning to disassemble and repaint the vehicle in 1-2 years from now. If the tank needs to come off for swapping out the crossmember and all the body panels have come off for paint, I'm debating if I should just replace the chassis at that point since most of the body parts except for engine and drive train will have to come off anyways for the paint job. Does this make sense? That would also be a good time to clean up all the stray and orphan wiring that I have going on. Are there other things to consider when going from a NAS V8 Chassis with 300tdi Engine Mounts to a 300tdi chassis? Will the old fuel tank fit? I think my chassis is in pretty good condition, perhaps I should just de-rust and galvanize it?

Integrated home made rear crossmember sounds like an excellent idea. I have a bolted on hitch currently and I was looking at the one Jack makes here on the board for replacement when the time comes.
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  #45  
Old June 12th, 2011, 04:47 PM
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Charles Galpin
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I can't help with the 300tdi questions, but definitely if you are planning to do all that in a year or three, then don't waste any time on it now! Wire wheel and clean it as well as you can and por15 or paint for now and forget about it. It essentially a cosmetic issue for the next couple of years.
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  #46  
Old June 12th, 2011, 05:05 PM
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Carl Jonsson
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That's where I'm heading. I was just caught a bit off guard because my rear crossmember looks pretty good. I knew there was rust inside but not to the point where I was able to poke a hole with a screwdriver. It made me worry about my chassis. It looks like in excellent condition but is it?
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  #47  
Old June 12th, 2011, 05:17 PM
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Charles Galpin
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I guess you'll know better once you strip it down. Personally if I was going that far I'd either galvanize the one I have or just replace it with a new galvy one.
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  #48  
Old June 12th, 2011, 09:18 PM
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barry f
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If you go with the frame replacement you just want to make sure you order a nas 90 frame with 300 tdi mounts. This will cover everything you need. Buying a 300 tdi frame and adding the nas gas tank mounts is doable but it will still cost the same so you might as well get the one you need that doesn't require modification. I think you can order it from the Richards chassis site.
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  #49  
Old June 12th, 2011, 09:53 PM
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Rich Campbell
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I got my rear crossmemeber with extensions from mike at manhattan euro parts for a great deal and had a local welder do the job at a great deal! Only rust on my truck now good as new.
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  #50  
Old June 12th, 2011, 10:14 PM
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Carl Jonsson
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Thanks fellas. I'm going to patch 'er up for now and swap the frame later. Barry you have a point. If I do replace it I should get the exact same kind I have now (NAS with 300tdi mounts) to save me any unpleasant surprises.
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