What have you done to your DEFENDER today?

lordhelemt

Well-known member
Another puller, better clamping, even longer breaker bar, two torches.

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The champ remains undefeated. This thing isn't coming off without damaging it. Time to buy another box.
I had the same problem bu there is no need to replace the box. Use a cut off wheel and cut a slot along the side of the arm. This will allow the the puller easily pop the arm off. A new arm isn’t too much.
 

erover82

Well-known member
I had the same problem bu there is no need to replace the box. Use a cut off wheel and cut a slot along the side of the arm. This will allow the the puller easily pop the arm off. A new arm isn’t too much.

I considered cutting it, and may do so, but part-way through working on this I noticed the input spline condition isn't great, and the steering rotation over center is a bit rough. Considering these RHD manual boxes sell for peanuts, it's probably best to get another in better condition. I may go ahead and cut it though just to see it through and inspect the internals.
 

erover82

Well-known member
Even though I had my doubts about this box, I hate unfinished business, so out the cutting disc of last resort came. Cut a slot and hit it with the BFH. Was actually able to fit the larger puller with a bit of persuasion.

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Crack. Even with weakening the arm, it took quite a bit of torque to get it to release.

We're in.

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Lots of fine metallic in the drained oil. Bearing races and rollers look good. I think I feel the rough spot around center on the input worm gear, but it's not that bad actually. Was able to restore some of the input splines with careful chisel strikes. This thing might be salvageable. Will sleep on it.
 

BarryO

Well-known member
I calibrated my fuel gauge...by running out of diesel on I-20 in Weatherford, TX. It turns out that if the needle just touches the red, that’s empty. Fortunately just a half a mile to a Harbor Freight for a fuel can and a short walk to Shell. A mother, daughter and granddaughter gave me a lift back to the truck.

And then I learned how to prime the fuel pump on my new Cummins.
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One of these days I'm gonna arrive around with a jerry can of fuel to see where empty really is on my rig.
 

FLY CUBS

Well-known member
Yesterday I rolled my 90 out of the garage for the first drive in 6 months. What started as a timing belt change on my 200tdi, turned into A LOT of repairs and upgrades. Granted I could have finished faster, but during the time I also wrangled the 2 kids while my wife and I work from home full time, dealt with a dying dog, adopted a new dog, partially finished my basement, had the holidays and bought a 2a 109 that needed minimal work to keep it driving. Having a Rover with a stereo and cup holders feels space age! Huge thanks to ZG for being great with sourcing parts. Here's what I can remember doing:

  1. Timing belt
  2. Oil change
  3. New power steering pump
  4. New power steering hoses
  5. New oil cooler hoses
  6. Added Boomslang headlight relay harness
  7. New front grill/plastics
  8. New badges
  9. Swapped the fuse panel from glass to blades
  10. Added VDO EGT Gauge
  11. Installed 4 inward facing jump seats
  12. Installed newish headliner with dynamat and dynaliner underneath
  13. Installed interior side trim with dynamat underneath
  14. Intalled Tuffy stereo box with headunit, added speakers to front doors and MudUK enclosures in rear. Dynamat in front doors.
  15. Repaired two rust spots in bulkhead floor with RN galvanized repair panel
  16. New alpine window seals
  17. Rebuilt heater box with new core and motor
  18. New floor mats
  19. Stainless front door bolt kit
  20. Sealed gutters and roof seams with SEM sealant
  21. Painted rear crossmember
I have someone coming Wednesday to do a full paint correction on it then I'm going to ceramic coat it this weekend to keep things protected. After that I'll wrap up the axle swap by installing the D1 front axle (did the rear last summer) and get some rubber for my tornado wheels- and sell the Wolf wheels and tires.
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Adding carpet to the front once I confirm I have the interior leaks beaten back down and then looking to do a safety devices cage later this year.
 

erover82

Well-known member
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Buttoned the box back up until the seal kit from RN arrives, or until I get another box to compare it with. Also served as a quick excuse to try out the new Makita 1/2 impact. "520 ft.lbs. of Fastening Torque and 740 ft.lbs. of Nut-Busting Torque" in a relatively compact package. Seems to whiz lugnuts off better than the old Craftsman Pro of similar size. Socket chosen for Jymmie's benefit.
 

jymmiejamz

Founding Member
Callsign: KN4JHI
Finally pulled the tank out of my D90 to find the fuel leak. The pump itself has cracked where the rusted lines go into the housing. Also noticed that the Genuine vent hose I installed 3 or 4 years ago is already very cracked.
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While I was back there I noticed a small prick in the fuel pump wire. I’m guessing at some point this truck had a crank and no start and the person used a multimeter probe to pierce the harness to check for power to the fuel pump. This is never a good idea and can allow corrosion to travel through the harness.
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erover82

Well-known member
Finally pulled the tank out of my D90 to find the fuel leak. The pump itself has cracked where the rusted lines go into the housing. Also noticed that the Genuine vent hose I installed 3 or 4 years ago is already very cracked.

I wonder if that hose isn't formulated for modern ethanol added fuel.
 

John Z

Well-known member
Added a rear vent from a JK wrangler to try and get more airflow from the front vents. It's seems to work well. It didn't go as planned since it was wider than I originally wanted. I wanted to fit it in the center between the structure of the rear door. But figured I'd give it a shot anyway. I liked that it looks to seal from water getting in.
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In the future when the rear door is eventually replaced when the rot gets bad enough I'll use the one from the TJ PN 5065432AC. Looks to be narrower.
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John Z

Well-known member
Is yours sealed well enough that when the fan is on the new rear flaps open?
I couldn't really watch it, but I did see light from the flaps.. What I had noticed a few weeks back was that if I had the fan on high and the vent open the air would almost stall where no air would flow from the front vents. I had to open the rear slider to get air to come out the vent. All the door weatherstripping is new, I think I sealed the roof of leaks.. so IDK..
 

jymmiejamz

Founding Member
Callsign: KN4JHI
Every modern car has vents like that in the rear to prevent the cabin from being pressurized when the HVAC fan is running. Early defenders had them in the roof. I wonder why Land Rover decided to eliminate them.
 

erover82

Well-known member
Every modern car has vents like that in the rear to prevent the cabin from being pressurized when the HVAC fan is running. Early defenders had them in the roof. I wonder why Land Rover decided to eliminate them.

No longer fitted from 1990 model year as they could/did allow water to be sucked in.
 

LazyRabbit

Well-known member
I calibrated my fuel gauge...by running out of diesel on I-20 in Weatherford, TX. It turns out that if the needle just touches the red, that’s empty. Fortunately just a half a mile to a Harbor Freight for a fuel can and a short walk to Shell. A mother, daughter and granddaughter gave me a lift back to the truck.

And then I learned how to prime the fuel pump on my new Cummins.
View attachment 18532
been there... when that fuel gauge touches the red, its EMPTY. A slight hill and you are done.
 

dkemm

Well-known member
Not all has been done today....but I have been busy with my '88 RHD 90.

I picked it up at the end of February and here is me list (not in exact order of completion) over the past (almost) 2 months:
Replaced clutch master cylinder - nice to be able to shift without having to pump the clutch
Electrical - reconnecting lights (correctly), fixing grounds, installing proper size fuses (physical size and amperage)
Front Bearings - tear apart, clean, inspect, repack
Suspension Bushes (bushings?) I think it still had the original rubber....well, what hadn't already cracked away
Lubricated all grease fittings
Fixed door latches & locks (passenger could only be opened from inside, neither lock worked)
Replaced door window wipe seals and some Uchannel felt
Drained and replaced all fluids (engine, tranny, Transfer case weren't too bad - had likely been serviced by previous owner
Drained axles and refilled....not sure the last time these were done....
Checked and cleaned all breather tubes (axles, Tranny, TC)
Electrical ...yes again....to fix clock and dash lights, installed stereo
installed LED turn signals all around (based on previous lighting findings/temp fixes)
Replaced hazard switch and ignition switch
Installed LED headlights (I can see at night now!!!)
replaced fuel sender and engine temp sender
Installed antenna for stereo (not that I listen to radio much) but didn't like the hole in the wing
replaced all tie rods/ball joints - went with all new bars and steering drop arm (trying to keep it in its lane)
repaired left swivel ball - had some play, and leaked - (amazing how well it stays in its lane now!!)
- I still plan to repair the Right side as well, but wasn't leaking as bad, didn't have as much play
Replaced steering damper
Added rubber cargo mat (for dog comfort)
Replaced Brake master cylinder - wasn't having problems....but the reservoir had visible age / UV cracking (accident waiting to happen)
replaced left brake line to caliper (looked previously kinked and attempt to straighten...)
Replaced Battery Box and seat box sheet metal
Replaced Coolant Overflow, flushed and flushed and flushed and filled with new coolant
temp fix on side rear windows to minimize rattle (used silicon tubing) - will fix this properly soon
Installed interior (front) light (previous owner had new interior/upholstery completed...but light not installed)
As I have been going through the 90, removing parts for repair...I have taken the time to clean them, wire wheel them, prime and paint Satin Black.

next steps.....a little more electrical.... I would really like to convert to blade fuses, as well as add the capacity to address future addons - lights, pwr locks, pwr windows
As the photo shows.....171K miles on it....not super high mileage in LR terms, but the engine is a 19J, I'm not sure it would get up to freeway speeds and only getting about 14mpg right now......so now....I just wait.....its been a month so far....but soon....the R2.8 will arrive, along with the HD R380 and HD 1.2 LT230.
I think after that....I might focus on looks....wheels, 33's, tire carrier, front bumper....maybe axle upgrades to ATB with new shafts
 

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rocky

NAS-ROW Addict
Under the I’m not finding the time to do it confession new WP and Allisport radiator... Top hose took a little figuring out but I think once it’s clamped down, refilled etc we’ll be good.
 

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