Bodsy

Hi All, I've recently aquired a 1996 Defender 110 County. It's overall in pretty good nick, but I knew when I bought it (at a good price ;-) ) that it needed a new rear crossmember. Thanks to this site, there was a great 'How to' in the technical archives. http://forums.lr4x4.com/index.php?showtopic=24885 I'd like to add a bit more feedback on it and possibly the thread could be updated. After a bit of research, I bought this rear cross member with extensions which was very similar to the one in the above post. http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=290765610490 Removal was as per the technical archive thread, with the usual changes such as a corroded fuel pipe jubilee clip and a few rusted bolts here and there. Getting the tank out, as the thread suggested was very tight on the sender unit against the chassis. I did manage to get it out, but my problem was on re-fitting. Because the chassis rails now had the extensions welded to part of them, they were a few mm thicker, exactly where the pipe needed to drag down the chassis. I couldnt get it in place without it breaking. Further examination of the fuel sender and I coiuld see there were some lugs (you can see one of them jus above the wire. A quick clean up with a soft wire brush and it was clearer. The whole unit can be turned in the tank and removed. As yoiu can see form the above pic, there is plenty of clearance to get it back in once it was in position. So, to remove, I used a small chisel ended punch and at an angle, tapped the lugs so they moved anti-clockwise. Once it started moving, it came out with a little fiddling to get the pipe and float out intact. I checked that the gasket was OK and once the tank was in place securely (without having to worry about breaking the stub on the sender unit) I just refitted and tapped it back around until it was secure. If I was to do the same job again, Id definately have a go at removing the sender before taking the tank out. Other jobs I did 'Whilst I was down there' Removed & discarded the Borg Self Levelling unit Changed the A Frame Balljoint Changed the Springs to HD and Shock Absorbers Changed the ARB drop links, new bolts everywhere and plenty of copper grease! New tail section of Exhaust Ive also got a Discovery 3 I've had from new and I have to say, it's great buying bits for the defender as everything is so cheap in comparison!!! The end result is that It went in for its MOT this morning and passed with flying colours! Result! Next job is to remove that new bit of exhaust and put the bracket on the right way round..... well we cant all be perfect now can we! But thanks anyway, a great guide, I'm sure I'll be using the other guides for the wheel bearings and CV joints! Cheers Bodsy ps, how can you tell if its had the timing belt mod to stop it trashing (although its done 142k, so would hope its already been done!)