Got the other side door top off by grinding the last nut off, the one that was spinning was actually sheared off in the door top (so the inserts were not spinning which is good) Managed OK to remove the glass by drilling out the rivets and it all came out easily I do not think they have ever...

OK got drivers side off by grinding off the nut that would not move. Took quite a bit of levering and hammering to get the studs through the holes in the door bottoms they were jammed full of rust. Got some stilsons on them to try and remove studs but one would snap if tried harder and the...

Cheers all I think I will cut the nut off the side I managed to get the other off. At least I can run a die down it and put a new nut on to reinstall (with plenty of copper grease) and see how it goes. My worry though is with the insert turning in the door top it would not be possible to cut off...

Tried to remove the door tops from ex military 90 and results were poor, got one nut off eventually but snapped one and the other two seem to be spinning in the door top but not undoing. I had been soaking in WD40 for a week and heated the nuts up before trying to remove. Any other experience of...

If not too late run it for 5 minutes before putting gearbox back on just to check. When I replaced mine and got it all back together it leaked and had to remove it all again. I had used a cheep imitation Dowty seal, the second time I got one from Turner Engineering which was much easier to fit...

I looked into using red lubeguard in my new box and searching on google found a comment on another site (american I think) saying that the red ludeguard was not good for manual gearbox syncromesh operation?? No idea if there is any truth or technical reason behind this comment but I opted not to...

To check syncromesh drive it using double de clutch like an old crash gearbox vehicle if it changes smoothly then it may well be syncromesh problem. (Cheers windy81 I'll just get used to rattle then on mine)

I have sealed my clutch housing to gearbox / engine block and clutch slave cylinder and starter motor to guard against water getting in when wading. I just wonder though would the bell housing and timing belt housing need to breathe if plugged and sealed? Different situation to gearbox and...

tottot Cheers yes will give that a go, I set it the same as the old one - when you think about its no wonder then I still have loads of play.

Feel for you I have just changed mine also and due to using a poor quality rear crank seal had to take it all off again. Now its all back together and running again I have remembered I did not fit the small plastic staple looking like clip that holds the clutch release bearing to the arm. It now...

The 90 just passed MOT 32 years old and no advisories:) I hate MOT's worse than going to Dentists

PTFE pipe thread tape works well also I use it on the gearbox / transferbox top up plugs also.

Nice one easy fix then

I had what sounded like similar noise which would happen when slowing down coming to a stop, in my case in the end it was bearings in the LT77 gearbox shot so had to fit a recon. When i got it out though the bronze spiggot bearing in the end of the crankshaft was also knackered I am told these...

Pretty sure they are not cast they look like they are made of welded together sections of pressed mild steel sections. Cast materials are usually brittle which would not suit an axle. The diff will be cast if you take a file to that and then the axle you will feel the difference. I am sure you...

Nice one hopefully that sorts it

Have you removed the part from the pump there is a brass washer / seal could try replacing that. You will get a replacement fitting from a local diesel injection place.

My 2.5NA was running hot for 2 years I changed every thing from sender to gauge flushed the system new water pump and thermostat and still ran hot. After all that someone mentioned you could get different temp thermostats so I changed to a cooler one which worked . They are tough engines did...

All back together and no leaks. Used the proper Dowty seal and got the 200tdi gasket. Thanks to all the above comments. Just have a weeping sump gasket to replace now and it really will be leak free (for a while).

Didnt know you could by them I made a couple about a year ago similar in size out of some 5mm rubber and just self tapped into place (fine on an old military). I was fed up of not being able to see through the window to the mirror. They work great at stopping mud being sprayed up the door and...