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Awesome stuff disco, thanks again, do you know what the panels are called, or a part number or something?

Morning all, I'm doing a rechassis of my 200tdi defender 90. Most of the body is off and so far not too many surprises! One surprise was the panel on the tub that the seat box bolts through on either side. Loads of aluminium corrosion and on the passenger side the bottom of the panel has turned...

Morning everyone, Got some really bad news the other weekend, my chassis is rotten along the bottom of the main sections, and under a few of the brackets so rather than spend a stupid amount of money getting plates welded to what I can only assume is bloody thin and rotten steel....I'm going...

The crowning thing may be what it is, have just taken the input gear out and it doesn't look very worn, neither does the mainshaft, there is a little bit of play which explains the clonking when changing gears but I can't work out whether its worth changing the input gear or not, there wasn't...

I assume by the way that the intermediate gear is the same thing as the input gear? As I know there is an intermediate gear in the transfer box but I take it you mean intermediate 'between' the two boxes. If it does turn out to be this will it have permanently damaged my gearbox at all? I just...

I've had it now for about 5k miles, and it hasn't got better or worse but there is an oil leak somewhere that I need to sort (dont think its related but just mentionning). Is there any way of testing if its the intermediate gear....or at least crossing off other possibilities? I reckon it...

Sorry to resurrect this thread but I'm in exactly the same boat, had a disco transfer box fitted to my defender and now it whines, they tried to tell me it was my gearbox, but it clearly isn't as it didn't do it before!! Anyways, if it helps you at all, mine is speed related too, but you do...

Hey all, Its all done, thanks for everyones advice! Got a terrible feeling I did the last set of 60 degree tightening wrong on the head bolts so I really do hope I'm worrying over nothing and that I did it right but we shall see!! So nice to have done all this, was actually good fun and my...

Yeah i'll upload some shiny sexy pics in a sec, just to double check something though, where the thermostat housing bolts onto the cylinder head, should there be a gasket there? They removed the housing to skim it, but there is no gasket, grrrrrrr

UPDATE: head is back from engineers, only needed 6 thou taken off, gasket comes in the morning along with head bolts, so I should be able to get it all back together tomorrow after work hopefully!

£35 + vat, thought that was quite good...not that I have much to go by. Is it best to use a rag and spend ages cleaning block rather than scraping it off with a putty knife or something?

UPDATE: found a really good motor engineering company in Pboro called Lyndale Engineering, they checked it this morning and its very very slightly warped, so they're gonna take off as little as they can and hopefully have it back to me this afternoon :) Measuring everything today for the gasket...

Right, head is off, basically no full on crack, but the area between one of the coolant holes and piston 2nd in from bulkhead side of engine has worn through and there is evidence of coolant getting to the ring on the gasket, and then loads of wet coolant mess heading out from there, so clearly...

Might as well do it to be safe then, only £40 + vat unless someone can recommend someone cheaper in Peterborough

Ok, will have the cylinder head off in a bit, didn't have time to get it all off yesterday having sheared off a crappy socket adapter!!! If I get the head off and cleaned and check it all over with an engineers rule for warping..is that ok or should I skim it? Only asking as the temp guage...

awesome stuff guys! Now to work hard, finish early and strip off the head :D fun times

Not that I have done it yet, but does this mean that if I want to tweak my turbo pump then a thicker one would be better....not sure if I'm going to though.

thanks again disco, fantastic help. Just because I'm generally interested, what makes a thinner gasket better...if you can use one that is. Screwfix have the mag stand and dial indicators so I'm sorted :D

Actually just found a great thread on measuring the protrusion, exactly as stated earlier by disco but seeing a few photos put it all into perspective. I'll invest in a dial measurer bob and clamp for it asap and go about measuring. It seems the no notch is often the lazy way out then?

just the first few places I looked didn't have the no notch gasket, and I wondered how much of a difference it would make. May look into the method for checking it a bit more but it does sound pretty difficult.