Hi yes it is a Dakar.
This is the web site http://www.dakar4x4.me.uk/
I'm a bit on hold at the moment as I still have some bits to get.
This may also effect your plans.
Steve Bennett the owner of Dakar was sadly killed in a road accident about a month ago.
The business was basically Steve and his partner Tori so it all depends on when/if she decides to continue. Either way I wish her all the best.
Steve
There are dowels between the halves which is not helping.
The pic in Haynes looks like there are 15 bolts.
There is a ring of bolts following the diameter of the housing then another four along the bottom which means a couple are almost out of sight underneath and behind the pulley if it is still fitted.
Steve
Is it possible the steering shaft may have slipped in the splines of one of the U/Js?
If it did then the U/Js would no longer be in line so may give the notchy feel.
Steve
The nature of the damage should give some sort of clue as to how it was caused.
If the rad is 'new', rather than a second hand, replacement then a repair should be fairly easy either by soldering, if copper, or epoxy resin if ali.
Steve
Don't know the 3.9 well but if it helps the 3.5 pump only runs during cranking and when the flapper MAF is open so if I want to check my pump I have to hold the flapper open with the ignition on. I think the 3.9 does a couple of seconds of pump prime when the ignition is first turned on but again I'm not sure.
You need a helper (to turn the key to crank) so that you can listen to the relay to ensure it is moving (notice I avoided saying 'working'). If it sounds OK then slide under the back and listen for the pump when your helper again tries to crank.
My 3.5 went through a spell of the pump not starting until the tank had been abused with a heavy shoe. Inevitably this method did not last and the pump had to be replaced.
Steve
Are you planning to eat off it?
If not, then leave it as it is unless there are specific components you feel the need to remove the mud from in which case the garden hose should be enough.
Steve
Are all the leads back in the right place on the alternator? Not sure on this but I think the ECU takes a pulse from the alt to know the engine is turning over.
Disturbing the bob weights is also high on the list despite your attempts to avoid it.
Steve
If the mirrors move to a programmed position as part of the memory system then shorts in the doors or pillars are very unlikely if they both move out of position together. To me this has to be the control module.
Steve
What tests did they do for sharp edges?
My understanding is the 2.5mm rad on anything they can touch with the test sphere but in the case of a 4x4 type vehicle they could crawl around underneath finding sharp edges on all manner of engine and tranny machinings.
Steve
Just been out to roll under the motor and have a look.
Using Mark I eyeball I would say the slot is about 40 degrees before TDC.
As has been said the marks are very light.
Steve
Are you sure it is leaking from the hose?
If it was working really hard it may have boiled the fluid. If it did then it will froth up and overflow the reservoir and run everywhere.
If the fluid is old then it may have some water in it which will further encourage it to boil.
Now it has cooled and the froth gone it may give no further trouble until you get it worked up again.
Steve
I have Aerocatch pins on my Dakar.
http://www.aerocatch.com/automotive-home.html
Don't know how you would fit them on the RRC unless you put a mounting bar across like the Dakar.
Steve
Thought I may find the info in Electronic Parts catalogue but am now confused.
EPC shows O/S outboard Port 24 And O/S inboard port 26.
Port 25 goes to N/S.
Steve
Had to do a double take.
Misread it first time and thought you were complaining about "forty quid to take a van" when you had only paid 15 for it.
Steve
Had a core plug fail up behind the manifold on SHMBOs XJ6.
Cleaned the area with a wire brush in flexi drive and coated the whole area with half an inch of body filler. It was still there 5 years later when the car went to the breakers.
Steve
I'm building a Dakar.
The side steps are the lowest point at 24" and front/rear bumpers are about 33" when standing on level ground.
I think I will need the 60" if I expect to lift it through its suspension travel such that a wheel comes of the ground.
Steve
A common factor here could be engine earth.
As well as looking at the engine earth cables (there should be more than one) try connecting the engine direct to the negative terminal on the battery with a jump lead cable and see if that helps.
Steve
ETA You may want to fill in your profile with a location etc. You never know, someone helpful on here may only live round the corner.
Damn, bet it will be me!!