Sidelights stuck on and gearbox swaps

[xmob]

I had a bad day yesterday, and I'm going to bore you with the whole story before I get to my point.  Sorry.   :?

Yesterday, my intention was to (at least start to) replace the gearbox on Stig, the 200tdi Disco.  For a number of reasons this didn't happen.  I'd enlisted a number of "assistants" but they all turned up with stories of woe.

• Not sure if the crane will support the gearbox


• Can't lift the car high enough to get gearbox out


• You're not going to get it done today (I know, I just want to start it!)


• When you remove the gearbox crossmember, the chassis sides bend inwards, meaning you can't get the crossmember back in   :?:


• Blah blah blah, cheers guys!

So, project cancelled.  

I decided to park up Stig in a place where I'd be able to get to him later in the week, which meant moving Jack, my SJ.  I opened the door and saw a load of wires hanging down in the foot well.  Huh?  Hang on a minute, where the [laxative munchie] is my Sony radio!?!?  Thieving scum!  The vehicle parked next to mine was in the same state too.  It's been a good few weeks since I last used Jack, so I have no idea when the radio went messing.  I spent the next half an hour jumping and swearing, then kinda calmed down when I realised my CB could have gone too.  If they'd taken that, I'd have been wanting blood.

Anyway, because Jack hasn't been used for so long the battery was flat.  I couldn't get any jump leads to him, so I had to move him.  The rear drums were siezed.  Attach a strop, drag him out with Stig, introduce him to the rear bumber of a nearby car.  That's another (fairly hefty) battle scar!

Right jump leads attached, Jack started.  Sidelights on Stig now on.  Don't remember turning them on, but I'll just switch them off.  The switch is off!   :?:   By now I'd had enough, and just took the fuses out.

So, anybody want to comment on the gearbox swap comments?
Got any ideas what's happened to my lights?

[hobbit]

When you remove the gearbox crossmember, the chassis sides bend inwards, meaning you can't get the crossmember back in

Bev will vouch thats a falicy

bit tight but clean the ends off and tap it in, no probs

Yes they are heavy, depending on the method of removal, depends on the tools you need

you can do it on the floor by having the vehicle raised on axle stands/ ramps, not the easiest of methods, using a transmission jack for the gearbox

A pit with the use of a transmission jack would work too

A 4  post ramp would do the job but you still need the use of some support to get the box out and in, but heavy and awkward to man handle and align back onto the engine


To lighten the load you could remove the transfer box first, but that makes more work


The lights may well be something to do with the radio snatch, there is a permanent live for the radio memory, and also is there a switchig wire from the sidelights for illuminating the radio when the lights are on? If so perhaps these 2 are touching?

That would be the first line to check

[muddysteve]

your dim dip unit on the sammy is goosed

its on the bulkhead up behind the glovebox, big heat sink looking thing, just unplug it.

you may need to short out a couple of conections on the plug to get you fog light working (only on some models)

Steve

[xmob]

Nah, it's the Disco with the side lights stuck on.

[xmob]

My (very brief) plan for changing the gearbox was this:

Remove centre console and all surrounding gubbins (already done)
Car up on ramps
Slacken off all nuts and bolts (props, cross member, bell housing etc)
Engine crane through door, supporting weight of gearbox from above
Undo everything
Lower gearbox onto a few skateboards (don't laugh, it worked for my fully loaded rear axle)
Withdraw gearbox
Reassemble in reverse order with new gearbox

It can't be that difficult, especially with helpers, surely?

[muddyweb]

Not sure if the crane will support the gearbox
Can't lift the car high enough to get gearbox out
You're not going to get it done today (I know, I just want to start it!)
When you remove the gearbox crossmember, the chassis sides bend inwards, meaning you can't get the crossmember back in   :?:

Erm...


Crane wont' support it...   If you take the transfer box and gearbox out separately... you can support it with your hands !  Besides... where are you going to put the crane.. the box comes out from the bottom.

Can't lift the car high enough...   I can't even imagine how they were thinking of taking the box out !

Not going to get it done today ???  Pah !

If you chassis bend inwards then you have some serious issues with your chassis.  Clean the surface rust off the ends, add a bit of copperslip if it is tight and use a rubber mallet, or a bottle jack and some block to ease it back in.


Tell them we think they are a bunch of slackers ;-)

[Wanderer]

Kev, Bev ( :lol: ) and I did Bev's on his V8 on Saturday and having done a 200 previously I'd say the 200 was the easier of the two with less issues ie the cross member or exhaust.

I can't got with this bit about the crossmember going back. Doddle.
The only real problem is with the weight of the boxes.

On a 200 we had to tip the engine right back to get at the top engine to bellhousing bolts but other than that it went fine.

Make sure you've got a decent clutch aligning tool or and old shaft.
It's difficult enough refitting it without having to worry if the pressure plate is lined up.

[xmob]

Tell them we think they are a bunch of slackers ;-)

I did, and I'm bringing Stig home to do it myself and prove them all wrong.  Anybody want to offer assistance.   :D   I have a kettle and lots of tea bags.

[hobbit]

Ed will, he loves working on the floor

But definately make sure you have enough support that box is heavy and unlike a car box where you can balance and drop them off on your chest, not be tried with this baby

Also as ed said take into account the engine supprt when the box comes out, which way will it tilt with nothing at the back holding it

[xmob]

take into account the engine supprt when the box comes out, which way will it tilt with nothing at the back holding it

Didn't think of that.   :?

[hobbit]

The v8 mountings are very forward on the block so it will need supporting on the rear of the sump (wish I had took some pics on Saturday now), ed can tell you about the tdi, not done one of them myself, have you tried one of these clutch centres to see what they want to change it themselves

Might not be too expensive, at least they will have some gear to do it with

[Xtremeteam]

did a crankshaft oil seal today on a 90 in just a shade under 6 hours & changed a gearbox on a 200tdi disco on fri/sat (3 n 3) now need to go n sleep cos im shattered

[Wanderer]

And that's doing it with the right equipment and garage.

It's the weight that kills you.
I have thought about making a frame that would bolt to the gearbox/transfer box and allow easier removal and replacement.

The lifting point would have to be near the COG though and it's not where you'd expect it to be.

We were using a four poster :) What I'd give to own that place....

The guy who owns it is into classic rally cars. He's got a cracking Ford Cortina Mk 1 with the cake slice rear lights. Mini Cooper and a Triumph stag that he's doing at the moment (not that the Stag is a rally car :)  )

[Xtremeteam]

t's the weight that kills you.
I have thought about making a frame that would bolt to the gearbox/transfer box and allow easier removal and replacement.

The lifting point would have to be near the COG though and it's not where you'd expect it to be.

if you look in the gen landrover workshop overhaul manual im sure there is a digram for a plate that you can make that attaches to the underside of the boxes,AFAIK there is 2 drawings,one for an auto & one for the manuals

[Wanderer]

I'll have a look Mikee Thanks.

[Xtremeteam]

only know this as my dad scratch fabed one for using in the garage at home to do Gboxes on our trucks

[hobbit]

Interesting,   ed get the book out, looks like we will be knocking something up there  :lol: