reb78

Hi Guys, Quick bit if advice to tell me what i think i already know! The pic is of the gasket where the overdrive i am fitting meets the transfer box. It has ripped and squeezed out as i torqued up the plate (to the specified torque). Do you reckon this will be ok or should i do what i think i need to do and pull the whole lot off and replace it? As i'm sure you can see from the photo. There is gasket sealant (prob too much) in there as well. Thanks in advance

Thats funny. I'm 6' and have tons of room. I wonder what we'd done differently.. I think its the best thing i've done apart from the tdi conversion!

Get a good set of second hand range rover classic seats. I did for £30 and they have transformed longer journeys in my defender so that i can get out of the car without being really stiff now. The runners are the same width apart as the defender ones but are not as long, so you either have to drill new holes for the back holes of the runners - or i mounted them on a frame that bolted into the old holes. I have the seat base tilted back as far as it goes and my thighs don't rub on the steering wheel. If the seat base is flat, my thighs are nowhere near the wheel. You will lose the middle seat if you do this as the armrests make them too wide to keep this, but i am going to custom build a cubby box into mine so this wasn't an issue.

How much did they quote if you don't mind me asking? I may be interested in something similar and would be curious to know how much i need to save up!

The overflow line runs back to the pump from the front injector doesn't it?

There was a post on the torques recently for a 200tdi......... Its a little higher on the torques with a 200tdi than a 300. New timing belt - tension to 19Nm used timing belt tension - to 17Nm I know what you mean about niggling thoughts keeping occuring telling you to check things.... I get it all the time and its a right pain

I'm sorry that i was right too!! Not a pleasing job to do when you've just done the clutch anyway. Hopefully it'll all be sorted now its cleaned up.

I transplanted mine from my TD to the new Tdi. it fits and works fine.

Ralph, I read the link you put up - bit off the topic, but it mentions that the LT77s slave cylinder is different. Does it mean different to the LT77 one? I've re-used the TD LT77 slave cylinder on an LT77s and it seems to work ok. Does this need changing ideally? Thanks

Sell it!! I bought one recently in good condition, heater box and matrix in good condition for £50. (I was desperate and it was complete). I'm sure you'd get something for it...

Most likely adjustment of the pedal is needed, but one other thought.....Is there any oil leaking out of the flywheel housing? could be the rear crank oil seal and when the engine and oils is warm perhaps it is leaking a little - causing oil contamination of the clutch plate/flywheel? Have a look at Westerns post at the bottom of this thread http://forums.lr4x4.com/index.php?showtopi...utch+adjustment for info on how to adjust the clutch...

Thanks for all the replies. Got the gaskets and the OD has arrived over the weekend. Just one more question.... The input gear assembly i will be removing is cross drilled as i've fitted a recon gearbox and wanted to avoid the worn gearbox mainshaft as suffered by the previous box which was used without a cross drilled input gear. The question really is - will the overdrive inhibit the lubrication of the mainshaft at all and cause mainshaft wear (as it is not cross drilled)? Is there anything to be done that can decrease the chances of this happening? Have you guys with overdrives experienced this wear as a result of fitting them? Thanks

Just been on to Devon 4x4. They do indeed stock all of the spares and can source more from the States according to the lady i spoke to. I have ordered a Gasket and Seal kit. Just gotta wait for it all to arrive now!

Just picked up a nearly new GKN overdrive and was wondering if, apart from the instructions supplied, anyone had any tips/recomendations for fitting/maintenance?? (110 LT77s with defender LT230 transfer box)

I found that torque wrenches that go that tight are really expensive - so i did what you said above on my 200tdi and put a long bar on the end of the wrench and did up really tight! Suprisingly, when i undid the crank bolt on my old 19J which had been to a garage and had the timing belt done. It was not very tight at all to undo and there was no loctite on the bolt. Add in £400 to do the belt (which was the last straw in getting garages to work on this vehicle) and it was not a well done job!

Its much tighter than that... The workshop manual says 333-350nm which is about 245-258 lb/ft. Its BLOOMIN tight - my torque wrench doesn't go anywhere near that and since it needed an extension bar and all my strength to undo it i did the same to do it back up after i'd made a tool to bolt to the pulley and lock it on the chassis.

I fitted the defender rad/intercooler exactly where my 19J rad sat -no need to lower the mounts - so as you have a defender rad/interccoler it should all fit. I used the old radiator mountngs too but had to grind a couple of slots to allow for where the bolts of the rad intercooler frame went. Offer it all up and you'll see where you need to cut. I had a mare with the engine mounts too although mine was difficult on the passenger side - a lot of wigglng/rocking and swearing eventually saw them in place!

Granada ones have been recommended by others on here. Perhaps the pulley from the current land rover one will bolt on to the ford unit hence you can use the land rover belt?

My TD did it as it was coming toward the end of its time. I think it was really high crank case pressure pushing it off. I suppose it could be a similar problem in yours even though it shouldn't suffer as much as the TD.

How do you tell which thermostat you have? I fitted a wing top 'scoop' vent, but can't decide if it really makes any difference - that probably means it doesn't!

I'm in PB if you need a hand with any of this if you decide to do it yourself. I've done a couple now - and if its just a clutch change, i suspect the way western describes may be easier than taking the whole box out. The gloves are the best way to keep your hands clean - keep your fingernails cut really short as well! I'm one of the vets up at the Royal Vet College so have the same problem when i come to operate after a weekend working on the landy! Sugar and washing up liquid works a treat ot get most of the muck off and a stiff nail brush to clean up properly!!

If its not the diode, it could also be one of the wires to the alternator earthing (perished rubber around the wire). I had this on an old Volvo of mine once. Check the wires that come out of the alternator over...

I also removed the bit of metal just under the fusebox. This comes out easily when the floor panels are removed and exposes all of the bellhousing bolts. The only thing i can think of that the others havenlt mentioned is be really careful not to overtighten any of the bolts that go into the alloy threads - i used to have a habit of doing this so i use a torque wrench where i can fit one in. However - someone else, not me for a change had ripped the thread in the bellhousing where the slave cylinder bolts on - luckily the hole is longer than the old bolt so i fitted a longer one and it was ok - for a while though i thought i'd have to remove the box again and replace the bellhousing with a spare one i have - my heart sank at the thought of this.

JST, Can you put this link up again please "Eitherpalce the air filter where it is on a 300tdi (as shown above) or use the TD position. on this here it shows as you suggest threading the bottom intercooler hose through the mounting - worked well for me and i than ran the 200tdi filter in the upright TD position with a changed top end (disco 300 tdi 3" to 2.5" reduction with crank breather and 90 deg change) " I cant seem to get it to open Thanks

Wouldn't his just glue the glass down?! Reckon you'd have to make some kind of framework that would sit where the old gasket went and set the mastic in it for 24hours - but this would still be messy!