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excossack



Member Since: 22 Feb 2012
Location: North West
Posts: 5843

United Kingdom 1999 Defender 110 Td5 SW Caledonian Blue
Mid Crossmember replacement
Yup my Mid Crossmember is a bit crusty and well....crap...might need to be replaced.
YRM do one with removable seat box mounts,

A quick search shows you can do it without removing the body.
Threads mention removing floor panels. Are these the ones under the 2nd row seats?

I did wonder if I can remove the sills either side and chop out the old mid crossmember and the slide the new one in? 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock
Post #912407 14th Jul 2021 7:13pm
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rallysteve



Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2227

United Kingdom 2002 Defender 110 Td5 DCPU Keswick Green
Not too tricky.

Remove the rear floor panel, cut the old one into three pieces so it can easily be removed, slide the new one back into position from the rear footwell., bolt on the mounts and sill brackets.

Just need to be careful of the plastic fuel lines on the TD5 as they pass over the crossmember.

Would advise you get the YRM one and also get the brackets which bolt between the c-post/sill and the crossmember from them as they will no doubt be a bit too crusty too.

Steve 02' 110 TD5 Double Cab Rebuild Thread
Post #912436 14th Jul 2021 10:01pm
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rallysteve



Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2227

United Kingdom 2002 Defender 110 Td5 DCPU Keswick Green
Also a handy recent video by LR Workshop:
 02' 110 TD5 Double Cab Rebuild Thread
Post #912437 14th Jul 2021 10:02pm
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excossack



Member Since: 22 Feb 2012
Location: North West
Posts: 5843

United Kingdom 1999 Defender 110 Td5 SW Caledonian Blue
Cheers Steve

According to YRM
"For ease of fitting these mid cross members have been manufactured with the two brackets separate, to facilitate fitting without the need to lift the body from the chassis, as they will just slide in."

Seems so simple and implies you dont need to remove the floor?.

Looking at the video, its rear seats out.
Floor between front seats and rear seats out. (after removing old rusty screws that hold the floor in)
Hack a few bolts, swear a lot and remove the old.

I was thinking, would it work if the new Mid crossmember was chopped in the middle and each half fitted and then bolted back together with a plate of the join ? 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock
Post #912466 15th Jul 2021 7:58am
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Intercept



Member Since: 27 Feb 2017
Location: Suffolk
Posts: 587

United Kingdom 2002 Defender 110 Td5 Black LE Java Black
See https://www.defender2.net/forum/topic70049.html for more pics and info. I didn't remove the side panels but I did remove the floor and suspect that the job would have been much more difficult without doing that. Once the floor is out you get access to various other areas that often need attention, so there's a secondary benefit too.
Post #912469 15th Jul 2021 8:21am
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excossack



Member Since: 22 Feb 2012
Location: North West
Posts: 5843

United Kingdom 1999 Defender 110 Td5 SW Caledonian Blue
Thanks Intercept, I think I did see your post when I did a bit of looking around. What a pleasant task it will be..... 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock
Post #912474 15th Jul 2021 9:06am
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rallysteve



Member Since: 10 Feb 2014
Location: Cumbria
Posts: 2227

United Kingdom 2002 Defender 110 Td5 DCPU Keswick Green
I would just take the 2nd row floor plate out, the crossmember will lose a lot of its strength if you cut it and re-join.

It really isnt too bad job if you have a bit of time and patience. An impact driver (https://www.toolstation.com/impact-driver-...lsrc=aw.ds) will help with some of the subborn floor fixings which you can take the opportunity to replace with stainless YRM ones. The M6 ones where the floor meets the sill i find easiest to just tighten until they snap as the thread is quite long and usually very crusty.

Might be worth also getting a roll of the foam tape to reseal the rear floor plate when you replace it.

Steve 02' 110 TD5 Double Cab Rebuild Thread
Post #912485 15th Jul 2021 10:08am
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excossack



Member Since: 22 Feb 2012
Location: North West
Posts: 5843

United Kingdom 1999 Defender 110 Td5 SW Caledonian Blue
It does sound like the best option to remove the floor.

I have an impact driver and trusty impact Makita and i think i have some foam tape in cupboard. 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock
Post #912490 15th Jul 2021 11:08am
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Slideywindows



Member Since: 09 Sep 2016
Location: North Essex
Posts: 1283

England 

Click image to enlarge


Tell me about it....
Post #912539 15th Jul 2021 5:09pm
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excossack



Member Since: 22 Feb 2012
Location: North West
Posts: 5843

United Kingdom 1999 Defender 110 Td5 SW Caledonian Blue
Mine has rotted around the chassis mount area Sad 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock
Post #912563 15th Jul 2021 6:21pm
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geobloke



Member Since: 06 Nov 2012
Location: Nottinghamshire
Posts: 4410

United Kingdom 
Re: Mid Crossmember replacement
excossack wrote:
Yup my Mid Crossmember is a bit crusty and well....crap...might need to be replaced.
YRM do one with removable seat box mounts,

A quick search shows you can do it without removing the body.
Threads mention removing floor panels. Are these the ones under the 2nd row seats?

I did wonder if I can remove the sills either side and chop out the old mid crossmember and the slide the new one in?


You have beaten me to this one Excossak, I have pondered on how best to replace this cross member a few times Rolling Eyes Good luck my friend Thumbs Up Thumbs Up
Post #912580 15th Jul 2021 7:59pm
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excossack



Member Since: 22 Feb 2012
Location: North West
Posts: 5843

United Kingdom 1999 Defender 110 Td5 SW Caledonian Blue
Cheers. Time to get new parts on order. 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock
Post #912697 16th Jul 2021 3:24pm
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excossack



Member Since: 22 Feb 2012
Location: North West
Posts: 5843

United Kingdom 1999 Defender 110 Td5 SW Caledonian Blue
Looking at
https://www.lrworkshop.com/diagrams/land-r...s_52716#32

I think I need a set of screws for the floor such as;
https://www.ebay.co.uk/itm/362946400854?ha...Sw~FFgMqju ?? 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock
Post #912707 16th Jul 2021 4:42pm
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excossack



Member Since: 22 Feb 2012
Location: North West
Posts: 5843

United Kingdom 1999 Defender 110 Td5 SW Caledonian Blue
Button pressed and YRM order in. Eeeek! 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock
Post #913019 19th Jul 2021 8:36am
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excossack



Member Since: 22 Feb 2012
Location: North West
Posts: 5843

United Kingdom 1999 Defender 110 Td5 SW Caledonian Blue
The parts from YRM turned up yesterday. Now t-washed and the first coat of Corroless black paint has been applied. 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock
Post #913528 22nd Jul 2021 7:19am
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