Lord Azrael

Can anyone shed a light on something that's troubling me with this? As the 3rd and 4th gear are removed showing the bush, Gazzar states it's a one piece item on his box which appears to be a late unit, whereas on mine which is a Suffix B it is also a one piece unit (which wasa found sheared into 3!) bt when ordering the parts from the catalogue it clearly shows it as a 2 piece unit FRC4076 & FRC4077 which is what I now have. Was there a late change to the 2 piece unit possibly to avoid the fracturing? Gazzar please come back, we're all dying to see more

Yes, that's what I meant with mine. By drilling through the barrel it actually released all of the pins inside therefore allowing the barrel to be removed with the external pin hole. It's a fiddly job though and it's probably just as quick taking the lock apart as you did.

As Pete said, there is a hole for releasing it if you have the key. I managed through careful drilling of the lock with a cobalt drill to get the mechanism freed off so I could pop the barrel out using this method on one of my spare locks, they are a bit of a pain though if you can't find the keys.

We used to have a 6 wheeler, but it was only 4wheel drive with a dead axle added. Good machine though!

Well, I've nearly caught up with you now as I got another crowbar and got the shaft out, so the gearbox itself is now off and cleaned up. The first of my new parts have arrived, just awaiting a few more deliveries. I had to get a new speedo housing too as the one was found to be damaged near the seal...hence why there was silicone sealant over the back! I've still got the shafts to strip down and the transfer box to start on.

I use tool chests and wall storage items. The ones you see in the picture are made by Zag from Israel and are really handy for quick access and a damn site tidier than standard shadow boards. I don't know whether these can still be obtained anywhere though, I bought them in Halfords years ago.

In the back of the Haynes manual in the supplement section it lists all of the changes through the suffixes, that's how I eventually identified my box.

Excellent post, and perfect timing too as I'm currently stripping a suffix B box down and have a suffix A to do afterwards. The only problem I'm having at the moment is removing the intermediate shaft, as it's stuck in pretty solid. I saw you used a crowbar, but I can't find mine at present...will have to keep looking. The normal pry bars I have have only managed to move it out a short distance so far. Where you've resorted to the chisel to remove the mainshaft nut though, I would recommend the purchase of the proper tool 600300 especially for refitting the new one. I know they're about £50 on ebay, but I've used mine a few times and it's bloody useful on the impact gun and well worth the money. Good luck with the rest of the rebuild, I'm following along nicely!

Thanks Western, you're a star!

Hi guys, I've recently inherited a 2.5 NA Diesel engine after I sadly lost my father a couple of months back. He'd stripped it completely down and the block is on an engine stand and has all of the other parts neatly laid out underneath. It was one of the many projects that he intended to do at some time but never got the chance. I fully intend to rebuild this myself now, although I'm not yet 100% sure which parts I'll still require as I know there were a few items he said we needed. anyway, the big question is what would be the best reference manual for rebuilding this exact engine? Someone once mentioned RAVE, which is good, but only appears to cover the Tdi's etc. Many thanks.

I must admit I wasn't aware of DeWalt going so far downhill. The majority of items we seem to buy nowadays seems to be made in PRC, which quite frankly is shocking. I will not now buy anything that comes from there as most of the items I've unwittingly bought over the years that have been have fallen apart pretty fast! I always carefully check the labels on items now, point of fact when I was in Halfords the other day eyeing up a new battery charger I looked at their own brand Diesel/High Power unit - Made in China....However, there was a nice big boxed unit below with the big logo stating Made In Germany...guess which I bought! If I had the choice of most products I'd buy British, except there's so few British products available now..if only the government would make it favourable to companies to produce items here, employ a British workforce, make our country strong again...nah, not likely I suppose As a Tool Store manager working with the RAF I certainly get to see a wide range of tools come through from all manner of manufacturers and I would say the ones that really have stood the test of time in gruelling aircraft maintenance from temp differences of +50 to -20 and some very over enthusiastic technicians who don't care about the tools as they're not theirs, Snap On have been the best closely followed by King Dick. On a persoanl note I also like the Halfords professional range, although I dread to think where they're made(?)