Time to say goodbye?

[Flying Torquewrench]

I did spend some money on a new brake pipe flaring tool. My old one was pretty useless and this one gets good reviews. It is also easier to use on the car. Taken the photo with my tablet so it is too big to add to this post. Bugger!!

[Flying Torquewrench]

Rick, I finally found your thread about your new exhaust. I listened to your youtube videos and it sounds good. Sounds pretty similar to mine since half the exhaust is missing.

Couple of questions. I think that I know the answer but I’ll ask them anyway.

-Have you informed your insurance company as it falls under modifications. If yes, (highly unlikely ) did it affect your premium?

-Did you have your exhaust approved, as it is not type approved?

-Any comments during the MOT, since it is not the original exhaust?

I have been considering installing a valve. Which either gives an “open pipe” or a normal exhaust. Bit like the trucks have.

[Flying Torquewrench]

The gearbox is finally out.

It is far from ideal doing it on your own whilst crawling underneath the car. Would have been a lot easier if I had a lift. Hey ho, it is what it is.

I hope that it will be picked up next week for a complete overhaul. Initially I thought about having a look myself but I have decided to let the professionals do it.

Taking the clutch and the flywheel off tomorrow.

Found a few areas of corrosion that need addressing but she is in reasonable condition for a 26 year old truck.

Unfortunately all the photoks I take with my phone or tablet are too big for the forum.

[solarman216]

No need to tell me about that, I did Briggies on the ground way back before I had the 2 post lift, I had to take the transfer box off to get it back, it was just too heavy and one sided and that was an auto, Rick

[Flying Torquewrench]

For installation, I do indeed think that it is easier to remove the transfer box. I got her off alright but trying to line everything up during installation is a whole new challenge. The thing just weighs a tonne. Even on a smooth concrete floor the weight makes it difficult to move the transmission jack. Not at all being helped by laying on your back/side/front instead of just standing up.

Removed the clutch and flywheel today. Truth to be told, the flywheel is not in a bad state. Yes, it is officially outside limits but it is in better condition than expected. Anyway, the new one is here so I might as well install it. Then the old one can go in the spares cabinet in case of emergency.

Hopefully find a gearbox repair/overhaul centre that takes on a Patrol gearbox on Monday. Called a couple yesterday but they all seem very reluctant to take on the work. Not really sure why, either because the gearbox is old and parts may be difficult to get or just because it is such a big gearbox.

Found a big bulge of corrosion on one of the chassis rails. Fortunately the gearbox is off as access is so much easier. Cut it out today and welded two new pieces in. Just needs sanding the welds smooth and a lick of paint.

Next up is the rear crankshaft oil seal. Seems silly not to replace it when the flywheel is off. Just didn’t expect that the oil sump also has to come off. That will be the job for tomorrow.

I am doing the front half first, then turn the truck around to improve access. Especially as the rear axle has to come off I just have more space when the truck is reversed into the garage.

[Flying Torquewrench]

Waiting to hear back from some gearbox repair shops if they take the work on. It is proving more difficult then expected to find somewhere to have it repaired.

Started on the sump removal yesterday but realised that I had no sealant in stock. So had to abandon that job.

Instead I made new brackets for the front anti roll bar. The left one was completely rotten through and the right one had a reasonable amount of corrosion. Made them out of some 50x50x5mm box. That should last for a while. They only need painting and they are finished.

When I removed the gearbox I noticed that the gearbox support bracket had some corrosion on the left hand side. It didn’t look as bad until I started cutting away the rot. Once I got back to good metal I stripped 8mm of 10mm thickness away. I haven’t decided yet if I repair the original bracket or buy some metal and make a new one.Building a new one might be easier then repairing the old one. I haven’t looked at the other side as there is also some corrosion on that side. It doesn’t seem as bad but I won’t know until I removed the corroded metal.

[Flying Torquewrench]

Found a way to reduce photo sizes. To start, a photo of the removed gearbox.

[Flying Torquewrench]

Clutch and flywheel.

[Flying Torquewrench]

The old flywheel after the clutch has been removed.

[Flying Torquewrench]

The rear crankshaft seal after the flywheel and cover plate have been removed.

[Flying Torquewrench]

Bit of corrosion on the chassis rail. Easy access when the gearbox is removed. Would be very difficult to get to with the gearbox in place. All cut out and repaired now.

[Flying Torquewrench]

Gone from this

[Flying Torquewrench]

To this

[Flying Torquewrench]

Side view of the gearbox support bracket. The corrosion is clearly visible.

[Flying Torquewrench]

Started to remove the affected metal.