Hi, I was wondering if anyone has ever tried to change the front output bearing on the transfer box (TD5 manual) with the box left in situ? Looking at it I thought it might be possible using a slide hammer or a made up puller to to pull the whole shaft with the bearing once the seal and circlip...

Yes, I remember when we dropped the tank to do some welding. We thought we'd run the fuel leven really low but the thing still weighed a ton. Ended up with it on a trolley jack using my knees to force it into place. Nearly killed me!!!

I'm now looking at doing the rest 1/3 chassis replacement this summer but I think I'll get a couple of strong friends around and buy them a few beers and chips

I did a clutch and spigot bearing for exactly the same reason on the drive using the engine hoist through the passenger door and strops around the box method. You have to have someone to work the hoist but I'm not particularly strong but I did separate the transfer box from the main box. To be...

I modified one of those simple G clamp kits by making up spacers to do the removal and refitting. I found that heat was also a necessary thing to aid the removal of the old swivel joints. I'm lucky in the fact that my day job is repairing vintage motorcycles so have a lathe and oxyacetylene to...

Thanks Griff. I really find those threads that just stop short with no conclusion or solution frustrating. As an aside, our boy Rocky is doing well so far. We have put him on antibiotics as a precaution and our girl Bella isn't showing any symptoms of KC. We're still a shell shocked over the...

Okay, I'm going to wrap this one up for now. Fitted a new OEM switch today and the issue is fixed. The car is behaving just as it should and running well. As Griff said, if you get everything ready and are nimble during the swap you might get away without having to bleed the system. I'd always...

That was what I was hoping and managed to do it with minimal fluid loss. I took it for a test drive and decided bleeding wasn't necessary.

Okay, I'm pretty sure I have the problem isolated. After much fiddling and trial and error it appears to be an intermittent fault with the infamous clutch switch. The thing that was throwing me was the intermittent nature of the symptoms. In the end I shorted the switch and the throttle issue...

Hi, I'm up near Shawbury but would have no problem driving over to you if I could use your Nanocom. I'd be very grateful and of course buy you a beer for the help. I'm going to try a few things today and make sure I've eliminated any simple issues. I could pm you to arrange a visit. Once again...

I've just read through a post you replied to concerning the same problem someone else was experiencing. The WSM says that battery voltage is delivered to the switch from pin 35 on the ECU. I'm measuring something around 11v on the Black with white tracer wire which seems a little down from my...

Hi, a few people seem to have had the same problem as we're having judging by posts on the interweb but none of them seem to end in a successful fix. The threads just seem to peter out and, I assume the person fixed the issue but didn't bother to post a solution. It's really frustrating but if I...

The ECU appears to output a voltage to the switch, I'm measuring as 11v and the switch appears to close and ground this output when the clutch is depressed. When you say the workshop manual is incorrect, what exactly is wrong? I've been using a downloaded 2001 version of RAVE. I think the manual...

Hi, thanks for the reply. No, the clutch isn't sticking and there's no fluid leak. It feels sometimes that there's a slight surge in the rpm's when changing up. It sot of feels like a mechanical throttle sticking but the TD5 being fly by wire somewhat rules this out. The accelerator pedal itself...

Hi everyone, I have noticed an odd problem with my normally very reliable 2000 Discovery 2 TD5 manual (no sunroof, no ACE). Okay, she's fairly high milage, 180k, but we'll maintained. Recently I've noticed when changing gear there seems to be an intermittent fault. On pressing the clutch and...

Hi, just wondering whether I'm missing something here... It appears that replacement rear spring mounting brackets/spring perches for D2 TD5's are readily available but I can't find replacements for the front ones. Does anyone know whether they're the same parts or interchangable? Given that...

Let Me know how much you'd like for it and what make it is and I'll see if it's better than the trade price I have from our supplier gemsdad. Also does anyone know what effect replacing the DMF has to the feel of the car etc?

I never fit cheap clutch kits as I've been in the business too long not to know they're a false economy. I learned that lesson about 30 years ago when I fitted a nasty pattern on a customer bought himself. The one I have lined up is a Valeo which I believe is OEM, not dirt cheap but with our...

We do have trade accounts with car parts companies but because we've only had the car less than a week so we haven't been able to check what the prices are like. Most bits are pretty reasonable but that pulley is nearly as much as a turbo!