Well peeps, its been a while, & a lot to go on about.
Right, I'm getting on for 80 now & realise I might have bitten off too much, so I searched everywhere for a mobile mechanic to fit the viscous coupling, but after weeks looking, no-one seemed interested, so I though 'what the hell, one bolt a day'!!
Managed to get 4 axle stands on wood blocks under the chassis so there was a good 1/2 metre under, 10 mins struggling, 20 mins recovering!! But somehow managed to remove & replace the coupling WHITHOUT removing the g/box cross member, renewed the transfer box oil, auto box oil & filter, found the prop shaft a bit awkward, changed the oil in both diffs, a little oil paste on the magnets, but not much really.
Removed all 4 callipers, discs, & back plates, they were a bit rusty so cleaned them up, Kurusted & painted. All 4 speed sensors came out very easily, & look spot on, discs were good, but as I already had all new stuff, it was fitted!!
Been running it back & forth on my 30m or so drive, 1,2,3, hi lo etc, but not long enough to check the gear changing, so I finally plucked up courage to run it around the block, I was really nervous for had it conked out, I had no way of getting it back, my drive is on an incline as well!!
It shot off eagerly enough, but i'm not sure is actually changed gear, seemed to be revving a fair bit, maybe I wasn't going fast enough.
It still starts instantly & everything electrical seems to work. So, 1st question, is there any way to check the speed sensors with a meter? I still haven't managed to get my Rovacom to talk to the car yet.
2, it shows 35 max, but the sus goes up & down ok,
3, SRS airbag fault,
4, I've had every connector I can find, pulled them & they ALL look like new, yellow ones & the ones in the footwells as well,
Still a bit concerned about the gearbox, the workshop manual states that any fault shows one of very many 'GEARBOX FAULT' on the dash, I get none at all, so im wondering about the oil, when I changed it, it was a bit brown-ish, & I couldnt get as much in as I took out, filled it till it ran out, through the gears, topped up until overflowing again, but still not as much as came out.
Could this be why it seems to rev whilst driving?? Do you think I should 'do the changing' cycle again & see if I can get more in?
Remember, this had been sat in a transport yard since 2014!