defender TD5 90, 2003 rear axle overhaul

Hi All

This is my first post... I have recently bought a defender TD5 90, 2003 year. its not exactly been well maintained, so is perhaps best described as a rolling overhaul project.
I decided to take it to a friendly mechanic friend to sort a few leaks, and fit a new clutch, also ended up fitting replacement main and transfer gearboxes (Ashcroft), both leaking oil badly, and popped out of gear occasionally, so as it was all coming out I bit the bullet and replaced them. also leaks on steering box, and fuel pressure regulator.

I should have it back later this week, then need to get my hands dirty and do some work myself... first job will be brakes, wheel bearings, suspension and bushes. but I cant decide whether to drop the entire rear axle off and overhaul all parts off the vehicle and clean and paint axle, or whether to keep it as rolling overhaul, i.e. do brakes one weekend, then springs/struts, then bushes etc.. any opinions on this, as I'm concerned I'm taking a big chunk of work which will end up taking me weeks before she's back on the road, then there's the front axle to do.

also I'm expecting every nut/bolt to be seized solid, so thought I would spray "plus gas" on them every evening for a week!.. to try and ease them.. has anyone used this, or can suggest any alternative penetrating thread ease substance... other than the heating.

cheers

steve

Plus Gas is the best I have come across.
I don't usually have the time to work off the vehicle, so usually end up underneath with eyes full of crap!... ideally I would remove the whole axle, you'll be able to clean and paint it much better, as well as retaining your eyesight...
If you have a good sturdy bench that can secure the axle, remove it in one lump, along with all the suspension links/arms/diff etc... alternatively use the vehicle as a brace and remove components, whilst the axle is firmly held in place... then rebuild it on the bench and re-fit as a recon unit.
... or scan ebay for a donor axle, rebuild that, swap over and sell your old one back on the bay... easier way to keep the car on the road...

thanks for reply... I actually hadn't thought about buying a donor axle..... could be a good option to keep it on the road, I shall have a look.

Thanks

If you have the facilities to remove the axle as a complete assembly (couple of sturdy axle stands are sufficient - i had built a trolley on castor wheels to roll the axle out rather than trying to wheel it out on its wheels), do so. Working off the vehicle is so much easier. You can strip, clean and rebuild a complete axle in a long day if you really put your mind to it. If you decide to paint it, you'll need a full weekend to allow the paint to cure.

I've done this sort of thing as a rolling rebuild doing the brakes one weekend https://www.landyzone.co.uk/land-rover/browns-brake-rebuild-thread.220055/, the suspension bushes over a couple of weekends a bit later https://www.landyzone.co.uk/land-rover/springs-and-things.239690/ and then finally the bearings and diff centres and seals https://www.landyzone.co.uk/land-rover/axle-refurbishments.272149/. So it's perfectly possible to do this sort of thing in stages without the car being out of action for more than a couple of days at a time. Of course, if you have somewhere to work other than the side of the road and a bit more time it's possible to do a lot more - clean everything up and paint it, and so on. Seeing as you're already an Ashcroft customer, I can recommend their limited slip diff centres. Well worth it if the budget allows.

Thanks for the links to your overhaul threads, enjoyed reading them, its much appreciated... there cracking!.. and you make it all sounds so easy as well.. mmmmmm.

Mr Brown

just wondering how your poly bushes have performed? I see this is a controversial subject

rockjunky said:

Mr Brown
just wondering how your poly bushes have performed? I see this is a controversial subject

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Ah, you're very kind. Most of the time I'm struggling with nuts and bolts that won't undo, bushes that won't come out, brakes that take ages to bleed through to a firm pedal and all the other frustrations of car repair. It's just when you string it all together with pictures it looks like it all happened fairly briskly. The polybushes were the slightly more expensive Superpro kit and will have been on for three years this autumn. They have been through their 3rd MOT successfully and seem to be holding up well. With this degree of longevity (in excess of the 36,000 mile warranty) I'd be happy to fit some more when they wear out.

Brown said:

Ah, you're very kind. Most of the time I'm struggling with nuts and bolts that won't undo, bushes that won't come out, brakes that take ages to bleed through to a firm pedal and all the other frustrations of car repair. It's just when you string it all together with pictures it looks like it all happened fairly briskly. The polybushes were the slightly more expensive Superpro kit and will have been on for three years this autumn. They have been through their 3rd MOT successfully and seem to be holding up well. With this degree of longevity (in excess of the 36,000 mile warranty) I'd be happy to fit some more when they wear out.

Click to expand...

Interesting... I just re-bushed mine, and plumped for genuine bushes as the originals had lasted 14years/115,000 miles... hoping the next set last that long... BUT I have just fitted the Superpro ones to replace the rubber genuine lower rear shock bushes, as my 90 seems to chew through them fast - not sure why?