What a ballache. Sorry to see things descend to that state. At least you're versed in what's needed to get it fixed. It's got me thinking I should pull and replace mine now while there's still something left on them. Keep yer chin up :D

I was going to hire a hoist but there just isn't any space to use it in me garage. Or store it. I figured something that's in my way all the time would get a bit tiresome. Or more tiresome than the job already is :D The static deadman works well if you're tight on space. I have been seriously...

That's a really good shout. I've observed people putting a big hole saw through the plastic bit underneath the sump plug to access it without the belly pan off. Might have to clean a bit of oil off the top of the plastic part, though.

Makes no sense to me, that. You'd think a revision to the service procedure to include that filter would be best. I take it you have (or had?) the sponge type and replace it regularly?

What Andy said :) The oil filter housing is plastic so be ginger. A 36mm socket will help remove it as there's no space to swing a big spanner. Don't be tempted to put all the oil in at once. Although the total capacity is 6.8ltr, you won't get that much in unless the engine and components are...

Thanks Nodge. That's knowledge I'll definitely be retaining for getting the 4WD back online. As I'm only 2WD, it'll be fine for now I suppose.

Part VII - Refit the gearbox and IRD... Gearbox was pretty straightforward. Using the rope and GriGri (rope device) and the jack, we lifted it back into place. The DIY alignment tool worked a treat as the gearbox slid on with no problems. No need to turn the engine over to align the splines...

I thought it was the opposite given the front wheels do most of the work. But I've been wrong before :D Rear tyres still got 6mm+ and that's all I'm bothered about with MOT imminent :eek: Been nursing a binding N/S/F brake so t'other tyre was on the limit, hence replacing two tyres! New discs...

Part VI - The clutch Not replaced flywheel. Despite the discolouration, it was still smooth and cleaned up nicely. I measured the amount of play by rocking it back and forth. The inner marks show the free play. The outer marks show where I could lightly rotate to. I didn't have another flywheel...

I will. It's funny how fast you forget some of the details so sooner the better :) I needed to tighten the strut tops after a few miles. I had quite an argy-bargy with the IRD side. You were with me all the way thanks to copy and paste :D

2 new tyres on't front. 195/80/15. Puncture forced the issue. New ones soooo much quieter than the old Hankook atrocities. Keeping this one for repair despite the rod being about three inches into the tyre. It's a near identical OD to the new Uniroyal Rallye so will serve as a half decent spare...

Oil looks OK to me. As you describe no real play in the rear drive pinion either, I'd be happy that the IRD lives to drive another day. Bottom guard can stay off for a bit unless you're travelling rutted and rocky tracks. I took mine off because it had a massive hole in it where someone had...

True words. Crankshaft is cast iron I believe so I can see how that could happen easily. Correct tools and method obviously the preferred option to avoid straining anything. I'm just saying it could work if you're desperate enough :)

Never tried it on the Hippo but worked a treat on me van. This method may raise a few eyebrows on the forum. 1. 1/2" drive, 6 sided, 22mm socket on a breaker bar with another suitably strong bar slid over the top for extra length. 2. Fit this assembly to the bolt (making sure it's all the way...

You'll get a fair gauge of the IRD's condition just by dropping and inspecting the oil. Any metallic sheen or a grey/opaque colour will indicate bearing failure. This means a recon IRD or strip down and rebuild with a service kit is the order of the day. I gave mine the thumbs up after my oil...

Part V - The gearbox (5 speed Getrag) Either the old slave was knackered already or I mullered it removing the box. It just fell apart so good job I had a new one to fit (from the Borg & Beck kit). There was a huge amount of black dust that used to be the clutch plate. A stiff brush and...

Interesting read. Recently fitted a new turbo with new actuator and solenoid and it all works fine. Might run the test out of curiosity but can't see it being a problem. Seems to be no need to recon the injectors as I was able to sort the lumpy idle (the actual problem I was chasing) by simply...

Part IV - Some cleaning...

I bet it is! How times have changed. Don't think VW did much 4x4 development after that era.

I want one of those! Got me remembering the days when I was after a T3 Syncro van.