Landy 90 SoS List - Tips Welcome

I have just driven my brother-in-law's Defender 90, 300 Tdi van home from being stuck on his drive. He is a lovely bloke and has ended up in a caring role for not so fab father-in-law. So we (my family and I) have decided we need to get his landy back to top form and surprise him at the inevitable funeral at some point in the next 1-2 years (guess of course).

He has owned it since nearly new and its a metallic green paint finish van with a set of Range Rover size alloys and all terrrains. It has hit 161,700 miles and it has become too expensive for him to maintain and keep on the road. I went down with a hammer and new handbrake kit as it had not been run for a few weeks and the handbrake sounded like it was jammed on. Three knocks of the hammer on the drum freed that and I filled up and headed the 110 miles home.

The good bits: It starts on the button and made it home and the engine sounds good at tickover and under load. 5 speed box works well. No transmission knocks, or engine rattles/knocks. The interior has a rubber load lining in the rear and is in good nick. No bodywork dents and has been driven and looked after by a former professional lorry driver who cares for his equipment. It had a new rear 1/4 chassis in the last 2 years.

The bad bits noticed so far:
1. Clutch slip was really bad. In 5th at 45mph would lose traction/slip so I eased off the throttle until it took a new hold and would creep it back up to 45mph. Strange that that was worse on hills (worst case down into 4th and coaching it along at 30mph) but also happened on the flat. Looks like may have end shaft oil leak so could be contaminated clutch?
2. Son was in the car with me enjoying his first landy trip and quite excited by the adventure we were willing it home. Wife and daughter were behind and can testify that on clutch slip or load it puffed out a lot of smoke. It was dark so need to check in daytime but sounds like minimum over fueling and tired valves/valve stem seals, worst case tired engine. Pulled strong in 5th until clutch slip commenced and I had to ease off to prevent clutch burn out.
3. Lacquer peeling from roof - needs respray
4. All glass rubbers need replacement
5. Headlight and rad grilles light grey sun faded
6.Rear wheel removed as allow external skin good but base of door frame rotten - remove skin onto new frame, or start again with secondhand or new door?
7. Foot plate steps to side and rear seized
8. Light rust underneath/dry (no waxoil) generally looks pretty solid and external panels good
9. Door window rubbers poor
Will dig into the pages of knowledge here but I believe the 300 Tdi capable of 250k miles if well looked after so thinking might be strip check all tolerances and rebuild with new shells, oil pump, head overhaul new valves seals etc might be a realistic possibility?
Replace input shaft seal and full clutch whilst at it.
Any early days tips from your collective experience at what to work through/check before engine removal? Best place for parts source and any engine machining found necessary down my way - Gloucester?

We plan to keep a rebuild book for him and make it a great surprise one day. He deserves it and we'll enjoy doing it for him. The younger family members can learn how it all works and get stuck in for their Uncle.

Early tips advice/things to add to check, or fix list appreciated.

Jer

1 With the engine needing most work it's out with it.With the 300tdi it is likely it is the crank seal that is leaking.Fix needs careful work and quality parts,check it out on this forum. Cam belt change. Change Gearbox and transferbox oil. Fit new clutch / clutch release / slave cyl / clutch release arm
6 Get a new door.
7 Chuck em.
8 Get some Dintrol on the chassis and inside as well.
9 easy job
Good luck,and good for you taking on this job.

Brilliant and you can play at being Fuzz and Tim at the same time

Looks a lovely piece of kit and what a worthy cause, good luck and ultimately enjoy the journey.

I'd check that the clutch master cylinder pushrod has some free play at rest before condemning the clutch- you never know!

I'm relatively new to this lark and can't offer much practical advice (other than a big plus one on a complete lube change and new timing belt). However, much kudos to you for taking this on and to your brother in law too. Reckon you know your stuff and (as already witnessed) there's plenty of nouse here. All the best Jer, stick up some more pics as you go hey?

Jer05 said:

2. Son was in the car with me enjoying his first landy trip and quite excited by the adventure we were willing it home. Wife and daughter were behind and can testify that on clutch slip or load it puffed out a lot of smoke. It was dark so need to check in daytime but sounds like minimum over fueling and tired valves/valve stem seals, worst case tired engine. Pulled strong in 5th until clutch slip commenced and I had to ease off to prevent clutch burn out.

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I would have a careful look at the injector pump and see if it has been played with. These engines should go for a comfortable 350k if serviced regularly and my own 200tdi has 280k on the clock and has not been rebuilt to the extent you are referring to yet. with only 162k on the clock unless it has been neglected it should be a long way from a tired engine. A good service and a check of the fuel pump to make sure it is not over-fueling may be all it needs. If it has stood for a while this will not help things, so after a service may benefit from an Italian tune up, or at least a little bit of use.