90 rebuildrebuild

alexc2701 · Apr 26, 2017

Been busy at work so not managed to get much done! Fitted rear wiper motor other day and Ordered all the bits for door seals glass clocks wiring new heater control cables (old ones bent) window motors new ignition barrel and locks and door handles. Got some carbon fibre sheet to make the clock mounting out of.
Went to fit heater cable today had ordered wrong one too short! Then ordered inspection plate cover and gasket and accidentally got two gaskets! Just throwing away money

Welded some exhaust mounts when had 5 mins. Still trying go source a new air cleaner!

Had to make some brackets thanks to Als measurements as door wasn't made for rear wiper!

No idea what my air cleaner is actually off! Guessing it's the origional v8 one?

Bad times when welding is the most relaxing part of your day
Hopefully attacking clocks when get time before or at the Weekend!

alexc2701 · Apr 26, 2017

Putting a new bumper on the D2 as old one was cracked took my only bit of free time! LEDS are a million times better though

GATSO · Apr 26, 2017

hi ,,,just a quick hijack ,,,sold milli for 13k in total, zero profit lol and 10k into my 90 and no body on her yet lol

I'm keeping this one ,,,,,,,,,,,,,,,,,,

Al2O3 · Apr 26, 2017

GATSO said:
hi ,,,just a quick hijack ,,,sold milli for 13k in total, zero profit lol and 10k into my 90 and no body on her yet lol I'm keeping this one ,,,,,,,,,,,,,,,,,,

You've got the body though!? Just haven't put it on?

GATSO · Apr 26, 2017

lol yeah needs paint tho,, skint at the min waiting to sell house, to down size

alexc2701 · Apr 26, 2017

GATSO said:
hi ,,,just a quick hijack ,,,sold milli for 13k in total, zero profit lol and 10k into my 90 and no body on her yet lol I'm keeping this one ,,,,,,,,,,,,,,,,,,

I don't know how you stomached selling her! Was a beaut. I think mine gana finish about 10. Hopefully less haha. Maybe more o.o
Please say for 10k you at least own the body

I don't understand the pricing on these so hit and miss! See some on for like 13 and they're not much to look at. Then others for 20 odd and nice yeah but still a 300 tdi

madness
How far off you think yours is?

Al2O3 · Apr 26, 2017

GATSO said:
lol yeah needs paint tho,, skint at the min waiting to sell house, to down size

Make sure the garage stays big! You can get good small houses with a double garage. I'd love a double garage.

alexc2701 · Apr 26, 2017

Al2O3 said:
Make sure the garage stays big! You can get good small houses with a double garage. I'd love a double garage.

I have a garage that's just full of work stuff an no way near big enough for a car... wish I'd brought somewhere with some space I could build a big one on! And no pesky neighbors!!!

alexc2701 · Apr 28, 2017

Few issues putting the new tdci heater ducting in to replace the 300 tdi one, washer bottle impinges after made up some brackets in a spare hour after work
Hopefully doesn't put it too close to anything hot

Swapped ignition barrels and heater control cables too (so awkward to get to the recirculation cable under the ducting)

In my ongoing good luck the coolant header is also leaking out the side seem so guessing it's cracked and needs replacing too

never ends!
Clocks tomorrow!

alexc2701 · Apr 30, 2017

Started clocks yesterday stripped down td5 clocks and modified loom to work with a 300tdi. Had to sent the temp gauge wire through a connection in the speedo which allows it to read properly with the different sender
Chopped off multiple and wired into a new one, to match the one I'm going to put on main loom.

Main loom wiring abit of a nightmare... many missing wires and ones that the colours don't correspond at all..

Gana try finish it off later and plug in. See what works and what doesn't! Just hope the knackered battery has enough juice to play with. The crimps for the warning light panel are awfull FYI for anyone planning to do. Get one with cables in and barrel crimp them. The crimps are the worst invention ever and hardly fit the hole.

Looks slightly less of a mess haha

Brown · Apr 30, 2017

That's a lot of wires to get right - hope it goes well.

I like the washer bottle placement so you can get at the motors easily. That looks a lot more convenient than most conventional setups where the motors are buried underneath.

alexc2701 · Apr 30, 2017

Brown said:
That's a lot of wires to get right - hope it goes well.

I like the washer bottle placement so you can get at the motors easily. That looks a lot more convenient than most conventional setups where the motors are buried underneath.

You and me both haha! Probably be asking on here when I've got the odd ones left over!
I had to move it as it fouled the tdci heater vent ducting (which isn't a great fit anyway to be fair) gana have to instant gasket it ; but in moving I didn't want it to foul the puma bonnet and be accessible, only place that made sense! For some reason it seems the two motor cables are joined together on this one so Gan have to split anyway. Just keep finding more problems with this wiring haha.
Does anyone know if the r380 disco transfer box has a high temp warning output?

Brown · Apr 30, 2017

I don't know whether there's a dedicated port for a temperature sensor on any of the standard transfer boxes, but I fitted one of these:

http://rockymountainspares.co.uk/product/mech-oil-temperature-gauge/

Once I'd fitted it, it became apparent that the transfer box got quite warm on long motorway runs. So I made myself an oil cooler system:

With a little pump that's wired to come on when it gets hot:

Now I know it works I must get the pipes and wires routed a bit more neatly!

alexc2701 · Apr 30, 2017

Brown said:
I don't know whether there's a dedicated port for a temperature sensor on any of the standard transfer boxes, but I fitted one of these:

http://rockymountainspares.co.uk/product/mech-oil-temperature-gauge/

Once I'd fitted it, it became apparent that the transfer box got quite warm on long motorway runs. So I made myself an oil cooler system:

With a little pump that's wired to come on when it gets hot:

Now I know it works I must get the pipes and wires routed a bit more neatly!

There's one on gearbox isn't there? I just can't seem to see it. My friend said his v8 came with 2. One on gearbox and one on transfer, not sure if maybe it's just a thing peculiar to v8 models thpugh
That looks good does it make a big diffirence? Make oil last longer I'd imagine

Brown · Apr 30, 2017

I've got an overdrive fitted, so the oil gets a bashing. If I thrashed it along the motorway and kept up with the white van men, I could get the oil temp really high. Now, I've got a temp sender tapped into the transfer box sump which triggers the relay to switch that pump on. So even after several hours of motorway driving, the temperature stays around 100 C. The overdrive instructions recommend keeping the temperature under 110 C so I'm happy. I believe EP 80W90 has a flashpoint of around 190 C so I'm keeping the oil happy too.

alexc2701 · Apr 30, 2017

Brown said:
I've got an overdrive fitted, so the oil gets a bashing. If I thrashed it along the motorway and kept up with the white van men, I could get the oil temp really high. Now, I've got a temp sender tapped into the transfer box sump which triggers the relay to switch that pump on. So even after several hours of motorway driving, the temperature stays around 100 C. The overdrive instructions recommend keeping the temperature under 110 C so I'm happy. I believe EP 80W90 has a flashpoint of around 190 C so I'm keeping the oil happy too.

Hahaha hey I have a white van

Isn't just the flash point continued heat degrades most oils and can make acidic breakdowns which ruins seals; only reason I ask is there's obviously a temp warning light for transmission oil on the new td5 guage and if I have the means to wire it in I'd rarther do it like dunno if it'd be an option on a 300 tdi motor though

Brown · Apr 30, 2017

Yes indeed, the cooler you can keep the oil the better it will work and the longer it will last.

I'm always impressed at how people can get the best part of 100 mph out of a big square metal box with a roofrack load of ladders on top. Often with an engine no bigger than mine.

alexc2701 · Apr 30, 2017

Brown said:
Yes indeed, the cooler you can keep the oil the better it will work and the longer it will last.

I'm always impressed at how people can get the best part of 100 mph out of a big square metal box with a roofrack load of ladders on top. Often with an engine no bigger than mine.

I've only done 100 in it once ee. Okay maybe twice...
Weight helps downhill haha
Gana go investigate it now. Any idea what a yellow and purple wire is? It looks important but not on diagram haha

Brown · Apr 30, 2017

Mine's a TD5 so the wiring will all be different no doubt, so I don't think my colour codings will map onto yours. Apart from basic stuff like earth wires tending to be black and lives tending to be brown or red. I've had a pretty good look at my Defender R380 gearbox and I can't see much in the way of provision for temperature sensors or oil cooler pipes. So maybe the ones intended for use in Discos or V8s had different casings.

alexc2701 · Apr 30, 2017

This wiring is breaking me. Never use second hand looms

So stuck not even sure what to do next! Got some bits working... slightly

90 rebuildrebuild

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