JP 90

Cheers 🍻 much appreciated

Hi, first time I’ve undertaken this job. 200tdi 90 with LT77 and LT230 22D308814E just got a recon lt77 from Ashcrofts and decided to do the input gear on the trans with the cross drilled version. stuck on pre loading as I’ve no idea what it should feel like when done. the shim fitted was 3.38 but with new bearings I could not move the input gear at all. I removed (got a shim kit from ashcrofts), put 2.85 in and used dti which said 1.5mm. I’m supposed to add shim plus end float and deduct 0.05 which gave me roughy 3.00. So I fitted 3 and can freely spin the input with no resistance to the extent it registered nothing on the spring Gauge at all. So I’ve upped the shims to 3.16. No end float detectable and getting approx 5lb resistance on the spring gauge but I can still quite easily turn the input gear by hand. Does this sound right? Sorry but I’m going crazy with it.

Next on my list is a gearbox change. i want to recon my LT77. I’ve never removed one before. The engine and box are out so access not a problem. I need to split it from the engine and trans. aside from removing all the bolts are there any pitfalls I need to be aware of?

Ok, just to clarify. They’re not broken and they’re standard springs. As others have said, it’s no doubt a load issue. I added some spring compressors and then ratcheted down the chassis to the axle and hey presto! They seat fine. I have just ordered a heavier duty ratchet strap though. should I leave the bottom damper nut till last? Once the engine etc is back in? I cannot seem to get enough thread through to attach a nut once all the washers and bushes are on. Thanks

But something is amiss because I cannot even pass the shock through the lower mounting plate enough to get the nut on. No thread visible. It seems to be because of the angle the chassis is at compared to the axle spring seat. I’ve tried it with and without turret fitted. I’ve tried ratcheting the chassis front down to the axle but I cannot ratchet it down enough and in any event, it just makes the springs arc under load. Not really sure what to do to be honest.

I don’t think they’re broken. They look the same on one end as they do on the other.

Ah right! Thanks.

Hi, I thought I was already a member of this forum but computer says no. So, thank you for letting me join. i have a 1993 200tdi Defender 90. i have just started refitting my new galv chassis, replacing worn out bits as I go. I’ve already hit a hitch whilst re attaching the front axle. Both radius arms are fitted, I’m reusing the coil springs as they’re in good condition. However, they don’t appear to seat onto the lower seats properly, it’s almost as if the axle needs to turn a few degrees. Ratcheting the chassis to the axle seats them better but the springs then appear arched. What am I doing wrong?