tonydrover

Just measured the current with the multimeter, it pulls around 4-5A, that shouldn't blow the 10A fuse. Measured the circuit resistance from the fuse and it's 1.6ohms. That works out at 7.5A on 12V, so again shouldn't blow the fuse. I'm wondering if you are correct with your dodgy switch theory. Maybe sometimes the switch causes it to draw more. Switch is the only bit that's different to before. There's the relay too, but it only uses that on intermittent.

not quite a direct swap. The matching wires in the loom don't match the same positions on the new switch connector. So I've had to modify the new switch so that they do. Gonna plug it all in tomorrow and we'll see what happens this time. Tried it before as a direct swap and the only thing that made the wipers move was pressing the washer

Are Insa Turbos a directional tyre? What do people do about rotating the tyres front to back and side to side etc to even the wear?

Thanks guy, I'll just buy a new stalk then. bit easier.

Looking at doing this mod to my 1986 90. Currently only has 2 speed wipers with push down once wipe (which doesn't work any more). Does the PRC 7370 stalk switch fit onto an older 90 steering column? The wiring I'm quite capable of (I'm an aircraft electrician) just not sure whether to order one of those stalk switches or use a separate intermittent switch.

It's all back together now and road tested (by I have missed driving that V8). Had some problems with the clutch, mostly sorted now. I think it has something to do with the V8 in it. There is a matching plate between the engine and the clutch bellhousing. When I took it all apart the clutch slave cylinder rod needed replacing, so I ordered one and changed it. When I put it back together clutch wouldn't disengage. Looked at the rod, and compared to the old one it's about 1-2" shorter. Straightened the old one and put it back in and clutch worked. Why would it need to be longer? Is it because of the adaptor plate, and the V8? I need a new one, cos it's obviously weekened now, but I can't find a part number. The old one does look like simply a length of threaded bar with 2 nuts on, perhaps that is what I need to do. Unless anyone knows of a good part number.

I would be happy if admin want to put all these into the technical archive for other peoples future reference. It is something I couldn't find anywhere before I started, so if it helps anyone I'll be glad.

Clutch release. Looks much tougher than the Landrover 90 version. http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-06/20160606_151403_zpsr3mhhojh.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=96

My solution to assembling the 1st/2nd synchro. Manual says hold springs in by hand........tried that, ended up pinging all over. So........ 1 tywrap and 1 plastic bag. http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/20160608_134813_zpsphjvxwc7.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=108

The cause of the initial problem. http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/20160608_115026_zpsutowb8o5.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=109 New one on left, collapsed one on right.

Strip down begins. http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-06/20160601_165941_zpsgvovc5kx.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=89 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-06/20160601_165948_zpszpwiyhyp.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=90 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-06/20160601_165952_zps3h5ygcoa.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=91 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-06/20160602_150006_zpsd7gjvnrz.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=92 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-06/20160602_150043_zpssa0aaheu.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=93 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-06/20160606_151403_zpsr3mhhojh.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=96 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-06/20160606_151533_zpsed3hgohb.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=97

Now for the on the bench photos. http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-05/20160531_183941_zpslvdhs2gy.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=84 Main box and transfer box on the newly built bench http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-05/20160531_183951_zpsbjc9xfek.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=85 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-05/20160531_183957_zps1djavthd.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=86 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-05/20160531_184003_zpsuxgjrase.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=87 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-05/20160531_184008_zpsrezzhanb.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=88

Ok that photo upload seemed to work. Now lets try some more .http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-05/20160531_163818_zpspnbo0dba.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=76 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-05/20160531_163827_zpsqrmbiaac.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=77 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-05/20160531_164611_zpsun4rpjam.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=78 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-05/20160531_164618_zpsde9tt6a2.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=79 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-05/20160531_181217_zpszyei33qy.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=80 http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-05/20160531_181945_zpsvuqybloa.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=83 That's pretty much all of the removal photos

http://s923.photobucket.com/user/suetonbrad/media/Mobile%20Uploads/2016-05/20160531_163811_zps8jcbm0vd.jpg.html?filters[user]=138390622&filters[recent]=1&sort=1&o=75 Gearbox coming out.

Tried all that......it didn't work. Sussed it in the end........I removed the reverse idler gear and put it in the casing on it's side, fitted the casing then flipped the reverse gear into it's correct position. Put the reverser shaft back in..........and Robert is ya mothers brother. Just discovered that the rear mainshaft castle-ated nut is goosed though, so job is on a stall until that turns up. I suppose I could fit the main box back to the car and wait for the bolt, but it wouldn't really make that much difference.

Rebuild begun, can't get the main box cover back on, it just jams up on the 1st/reverse cogs. Is there some special knack to getting it past the reverse cog?

Yep, its definitely a series 3 box. I have also found a receipt in the extensive paperwork file I got with it for a gearbox/transfer box removal with the innards replaced and all refitted in 2011, which explains why most of it looks fairly new (for a 52 year old car). Some parts were worn (the front plastic bearing obviously), and have now been replaced. Just waiting for a gasket kit to turn up from Paddocks then I can continue the rebuild. I have tried various ways to upload all my photos but nothing is working.They are all on my facebook page though, so maybe if we could link to that somehow?? Search Tony Stobart if you are interested in the pics. I would love to put them on here somewhere for someone else's reference when they come to rebuild theirs.

Got the box in even more bits now. Looks like 1st/2nd synchroniser is goosed plus the springs and balls all vanished once I took it apart. Figured I'd buy a new one but can't seem to find out which is the correct one. Begining to think it has a series 3 gearbox fitted, partly because it has a 1st/2nd synchro and that isn't supposed to be until series 3, plus I have never had to double clutch it to change gear. The gearbox has this number on it 25174812C. Does that mean it's a suffix C gearbox?

Right I have both the transfer box and the main gearbox removed from the car and on the bench. Currently taking the main box apart. I would like to document the strip with photos etc for other people to refer to. Can't get the photos from my phone onto the laptop, must be a way, just can't find it yet.

Don't suppose you have any idea where I could get those steel caged bearings from?

I think maybe you experts are correct. I tried to take it for a drive today, and straight away something didn't feel right. Felt like the brakes were binding. Ruled all brakes out, and it was still the same. Something in the gearbox is binding, looks like it's gonna have to come out after all !!!!

Sounds like that is what has happened. When we were recovering there was a strong smell of clutch burning, which we thought was the problem initially, until we realised the clutch was still disengaging and re-engaging fine. We were just stuck in gear. Seems to me that all that melted plastic had effectively glued the 4th synchro into 4th gear. Hopefully it's fixed now. Ideally I suppose that should be replaced, but looking at it in the boroscope, it looks OK and probably not worth the hasle of taking the gearbox apart.

This is what I saw on the boro scope stuck in the 4th gears. Where would that have come from? Gearbox was empty of oil by now. Run it for a bit to get it hot, and plastic melted a bit/enough to release it from 4th. Filled it up again and run/flushed it, then drained it again. Got loads of little bits of plastic out this time. Rebuilt it and run it but only had enough oil for half full, so couldn't go for a drive. Managed to get in and out of all gears with transfer box in neutral. With transfer on low & high could feel it trying to pull, so will fill with oil (after I have got some more tomorrow) and go for a drive. That last photo is after all cleared out. What is that smooth white bit between the gears? Is that supposed to be there? Could that be where all that plastic swarf came from?

Borrowed a fancy piece of kit from work to have a look inside with. (A Snap on boroscope)

That is what it seems like......something wedged in it. As long as it's not a tooth off a gear!!!