[Discovery TD5 workshop manual]

As the title says has anyone got any live links for a free download of the above manual. Cheers in advance for any help.

[Charging a spare battery on the move]

If your charging a 12v battery, do it without the inverter

[series roofrack onto Defender]

I've just bought an old roof rack by Brownchurch, which has only one way of attaching to the gutter of the Defender and is through the feet of the rack, with 6mm bolts bolted thru newly drilled holes into the gutter, which afterr eading " Puma gutter", I'm not so sure, do you think it will be ok, its going on an 1994 110 Defender , so not brand new but I also didn't want big rotten holes in 10 years time. cheers Brian

[300tdi aircon belt]

Thank you Bob, that was more like the reply I was after, don't suppose you have a number on the belt , do you,

cheers

Brian

[300tdi aircon belt]

Hi, I have the aircon pump fitted for onboard air on my Defender 300tdi, but I want to fit onboard air on my other Defender 300tdi, but I haven't got the tensioner or idler pulleys, just the aircon pump with saddle and I was wondering if anyone has fitted a smaller belt without the other pulleys, and if they knew the part number or vehicle it applied to, cheers Brian

[2.4 defender axles]

will axles fron a 2.4 Defender 110 fit a 300tdi 110 chassis,

cheers Brian

[Discovery flashing faults]

Does anyone know what the M+S and a zero with a diagonal line flashing on the dashboard means, also the engine will not start, but has been sat for a year or two, cheers

Brian

[td5 gearbox]

I thought there was something like that, cheers

Brian

[td5 gearbox]

will a Defender td5 gearbox bolt straight on to a 300tdi engined Defender , or does the bell housing need changing , cheers in advance .

Brian

[Strange heater issue]

sounds like the armature is knackered, a break in the wiring, or you could try cleaning the rotor where the brushes contact with a bit emery paper .

Brian

[300 TDI alternator]

put a bar across the two bolt heads while loosing the other, or put a socket on a tommy bar and loosen off that.

Brian

[FCAW, no Gas MIG, Fluxo MIG...]

when using fluxcord wire , you don't need the shroud(chrome cover over end where wire comes out), handy when space is tight, but means the end is live, have fun with your new toy.

Brian

[Quick release bracket ideas wanted]

I have a similiar idea as above but use a large plastic spring clamp as listed here http://www.ebay.co.uk/itm/LARGE-PLASTIC-SPRING-CLAMP-CLIP-6-EASY-GRIP-MARKETSTALL-WORK-BUILDING-CLIP-/281055358398?pt=UK_Hand_Tools_Equipment&hash=item4170346dbe tha led lamp is bolted thru one side and can be moved quickly, I use mine for camping and working on the motor.

Brian

[transfer box locked]

From our LT230 FAQ's :

I have checked the adjustment but it won't come out of diff lock.

This is often reported after recent off roading, the centre diff is there to allow the props to turn at different speeds when cornering to stop drivetrain wind up, the speed difference is quite small and the centre diff gears are only designed to cope with these low speeds. If you are off road on snow or ice and you get wheelspin from one front wheel, what will happen is the rear prop will not be moving, the front will thus be going double speed, this means the small centre diff gears will be spinning like fury and after a matter of only a few seconds the plant gears will friction weld to the cross pins and the gears will fail etc, the result of this is that the diff will then behave as if it is locked as it in jammed with gear debris. The can happen if the driver forgets to lock the centre diff on a low traction surface or due to incorrect linkage adjustment, Please note this failure is not covered under warranty as we deem this driver error, the diff will never fail for any other reason other than excessive spinning, in which case the diff should have been locked by the driver.

Dave

that explains a lot, and now I have a knackered r380 gearbox aswell, all down to poor linkage, cheers for the well described reply

Brian

[transfer box locked]

mmmm, there is a lot of play on the transfer gear stick. The lever on the bottom is already pointing towards the passenger, but its giving the symtoms of a locked transfer box, I havn't jacked a wheel up yet, but I am convinced its locked, shuddering when turning, feels like its winding up, and today I went round a roundabout twice, and within a hundred metres a loud bang followed by some real nasty grinding, limped home, reversed it slightly to park and noise just disappeared , like nothing was the matter, but still I think its locked . could it have locked itself somehow, without needing the lever .

Brian

[transfer box locked]

LT 230 transfer box

In what direction should the link at the bottom of the transfer box be pointing, for it to be unlocked and locked, cheers in advance.

Brian

[new 300tdi cylinder head leaking before start up]

it was a three layer one, all separate two steel outer with a composite inner, deck was nice and clean

[new 300tdi cylinder head leaking before start up]

Ive had a good look, and it looks like it straight out from the head gasket, definately not the core plug, I've wiped the wet bit and you can see it weeping from the gasket, at the very back , and very back right hand side.

[new 300tdi cylinder head leaking before start up]

just finished putting a new 300tdi cylinder head and new gasket on today after having the whole xmas bad , passing the sickness flu around the house with the kids.

Its was all torqued up according to the manual.

As soon as I started filling with water I noticed coolant leaking from the rear of engine, a drip five every seconds, thought strange, thought maybe it might go after firing up but still there. The cylinder head and gasket are from Paddocks, any thoughts.

Brian

[300tdi water pump bolt]

be ready to usher any kids away as the swearing can get intense!

[300tdi water pump bolt]

I had this exact problem a month back,, tried welding on a big nut and the stud snapped below the surface, like you I put it back together till I could get it sorted. When I did sort it out, I damaged the housing that the water pump attaches to , as the only way was levering and hammering at the same time as the bolt was corroded along its length, within the housing. I guess I could of reused it but it was unsightly , just may be wise to get a spare just in case . Hope you have better look, cheers Brian

[200tdi Chripping noise]

try turning the belt round

[how do you get the injectors out?]

If you don't have access to a welder , bolt a heavy weight to bit of chain bolted to the injecter nut, quite effective

[valve seat missings]

yeah, had that confirmed today at the reskimmers when I picked up the old cylinder head, just had a sickly feeling when looked at microcat, but hoped for the better,

Brian

[valve seat missings]

nearly completed fitting new 300tdi cylinder head, and been looking on microcat and noticed some insert inlet/exhaust valve seats, are new complete cylinder heads with springs and valves supplied with these already, or should I have put them in.

Brian