OK, the gearbox is in the back of the car now. I'm under serious time pressures with this...we are moving house at the end of the month and I really need the Defender back on the road for then. I'm also on holiday next week so my plan is drop it off at Ashcroft on the way to the airport and get a new one sent up in time for next weekend and I can spend a few evenings putting it back in. But if I could get some more advice off you technical people that would be marvellous!
Firstly, this picture of mechanical horribleness. At the back, we have a FUBAR'd spigot bush. I take it this is just a standard part...or does it matter that I have a mish-mash of Disco 200Tdi engine and I'm swapping my longstick suffix E LT77 for a G/H?
At the front, on the left, rather worryingly is something I fished out the bottom of the transfer box when I took the bottom cover off. I'm 99% sure it's the bottom of the selector thingy off the hi/low lever, the bottom piece of part 10 in the below drawing. I took this assembly off, and the fork thingy is present and correct (and all that stuff was working fine before I took the truck off the road), but at some point that lever and cover mechanism (held down with 6 bolts) has clearly been off as there was a badly applied instant gasket stuff under it. So, I reckon at some point it's snapped off, some orangutan has taken the lever off, replaced the broken selector, and not looked for the snapped off piece or bothered dropping the bottom cover off. Thank feck it didn't end getting tangled up with the rest of the internals! Can I just check that those in the know agree with my diagnosis?
The piece in the middle of my photo is magnetic, same as the swarf catcher thing in the main box. Where has this come from as I didn't think there was a swarf catcher in a transfer box? Or is it the end of a mechanics pick up tool once he'd given up on trying to find the fork selector thing?
Thing on the right...no idea, probably a piece of that selector again.
Next picture is this one...
...and unless I'm mistaken this is a perfectly good cross drilled transfer box input gear with no wear which will happily live again. Are we in agreement?
And finally some of the clutch. Now I don't have a new one to compare it to, but to me this looks pretty good and can probably go straight back in. Any comments, or should it be a certain thickness (I can mic it up to check). Having come this far I'm happy to change it if needed, however as the Landy really won't be doing many miles, if this is perfectly serviceable, I'm very happy to make a saving here...
And lastly one sorry looking 110 cab! Need to keep going...we'll get there!
