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| rallysteve Member Since: 10 Feb 2014 Location: Cumbria Posts: 2237   
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Finally got hold of a replacement 1.4 ratio transfer box. Managed to get a low mileage TD5 item as it was one of the ones produced with a 1.6 ratio sticker on it.
Fitted it without too much of an issue. The handbrake mechanism was a bit fiddly to replace but no issues. Had to put an econoseal connector on the diff lock switch in place of the Sumitomo one. Much better than the old diff lock switch with spade terminals. Also replaced the gearbox oil with some fresh MTF94. Gearing is much better now. Need to investigate the gear selector though as 5th gear is very tricky to get. Fitted a new flatdog steering guard though:  Click image to enlarge Steve 02' 110 TD5 Double Cab Rebuild Thread |
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16th Aug 2019 5:18pm |
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| rallysteve Member Since: 10 Feb 2014 Location: Cumbria Posts: 2237
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Have had a persistent issue with a coolant weep from the thermostat housing. I knew one of the threads on the retaining bolts was a bit dodgy so decided to fix it properly as there was a constant puddle sitting in the valley gasket. Had a quick drive over to Paddock spares at Matlock Saturday morning for a new thermostat gasket and valley gasket. Amusingly the unbranded, unpackaged thermostat gasket was better quality than the genuine one i used before and only cost 90p!
To get good access to helicoil it, i decided it would be best to remove the inlet manifold: Click image to enlarge Click image to enlarge Two M8 helicoils installed with new caphead bolts and a proper gasket now: Click image to enlarge Click image to enlarge I was going to reuse the coolant as its not long been in but managed to miss the tub superbly when emptying it. Cue a quick trip to Halfords before they shut for some overpriced antifreeze. Since fitting a new thermostat, its been a  to bleed and warm up is pretty erratic so drilled a new 3.5mm bleed hole in the 'stat. Bled up much easier this time.
Click image to enlarge All back together and running better than before i think. No sign of leaks and it certainly got up to temperature sitting in traffic in almost 30deg weather on the way back to the workshop as it seems everyone headed into the Peak District this weekend. Click image to enlarge Cheers, Steve 02' 110 TD5 Double Cab Rebuild Thread |
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25th Aug 2019 8:14pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10810 
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Good news that you have sorted out the leaking issue
 1996 Golf Blue 300Tdi 110 Pick up.
Keeper. Clayton. |
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28th Aug 2019 7:44pm |
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| rallysteve Member Since: 10 Feb 2014 Location: Cumbria Posts: 2237
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Cheers
Coolant will have to come out again shortly as the water pump bearing had a bit of play in it, although not yet leaking, so I will change is sooner rather than later. Cheers, Steve 02' 110 TD5 Double Cab Rebuild Thread |
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2nd Sep 2019 7:21am |
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| rallysteve Member Since: 10 Feb 2014 Location: Cumbria Posts: 2237
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Finally had enough of the stupid static seatbelts that make leaning forward at junctions hard and are always getting trapped in the door so ordered some 3point inertia belts (in sporty blue
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Click image to enlarge Made up a couple of brackets from 4mm steel and bolted them through the original mounting brackets which brace to the tub, seatbox and mid outriggers. Excuse the dusty seats, had been lying on the floor and was rushing to get finished before i went home. Didn't get chance to refit the cubby either. Steve 02' 110 TD5 Double Cab Rebuild Thread |
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9th Sep 2019 6:12pm |
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| L110CDL Member Since: 31 Oct 2015 Location: Devon Posts: 10810
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Like the sporty blue there
Another day will finish the cubby box 1996 Golf Blue 300Tdi 110 Pick up.
Keeper. Clayton. |
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19th Sep 2019 7:21pm |
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| excossack Member Since: 22 Feb 2012 Location: North West Posts: 5857 
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Nice build. Over on Deboss garage on YouTube they are doing an international quarantine car show. On the judging panel are the chaps from Bad Obsession Motorsport (covering the Bracket category, naturally) 1999 Defender TD5 110
Regards John M0VAZ Econet Station 48 no clock |
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28th Apr 2020 8:55am |
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| Hufflepuff Member Since: 25 Oct 2014 Location: Hampshire Posts: 727 
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Hello Steve, what a fantastic build and thread! Of particular interest to me is the wiring labels you made, would you mind telling me what tools you used to create them please? I would like to do something similar on my own build. 2005 Td5 90 XS 1989 V8 110 CSW |
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19th May 2020 12:11pm |
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| rallysteve Member Since: 10 Feb 2014 Location: Cumbria Posts: 2237
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Thanks, sorry I missed your original question!
Those cable numbers are simply made using a cheap handheld brother label printer (mine was an Aldi special buy years ago but Screwfix/Amazon etc do them). I use 9mm width tape which is the flexible type intended for cable marking. As they dont really stick well on that size of cable (and they are intended to be used like flags) i then place a length of clear heatshrink over them to seal them up. Just make sure you use a hot air gun to shrink them rather than flame as it will discolour clear heatshrink. I use this method on most of my wiring that needs labelling (including my whole house when i rewired) it is a little sad but pleases my OCD 
Cheers Steve 02' 110 TD5 Double Cab Rebuild Thread Last edited by rallysteve on 1st Jun 2020 12:04pm. Edited 1 time in total |
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1st Jun 2020 11:14am |
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| Co1 Member Since: 19 Aug 2018 Location: North Yorkshire Posts: 3685 
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That pleases my OCD no end Steve!!
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1st Jun 2020 11:43am |
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| Hufflepuff Member Since: 25 Oct 2014 Location: Hampshire Posts: 727
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That's great, thanks Steve. I'll look at the Screwfix website. 2005 Td5 90 XS 1989 V8 110 CSW |
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1st Jun 2020 1:39pm |
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| Shroppy Member Since: 25 Feb 2016 Location: Shropshire Posts: 866 
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I've just read this from start to finish, great workmanship!
Would you mind sharing the source of your fuel and oil hoses (and fittings) please? I'm keen to do something similar for the 130. Also, did you manage to find all the necessary connectors for your looms to mate with the TD5 bulkhead loom? I'll be doing something similar for the chassis loom I think. 1985 127 V8 Build Thread Series 2 109" Series 1 80" |
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1st Jun 2020 2:35pm |
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| rallysteve Member Since: 10 Feb 2014 Location: Cumbria Posts: 2237
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Thanks
Sure, pretty much all of my braided hose and AN fittings came from Alex at Torques UK. The quality of the stuff he supplies and the customer service has always been faultless. I did use all the correct connectors to mate with the TD5 bulkhead loom (e.g. engine sensors, rear lighting, LH & RH wings) which are all Sumitomo HW 090 connectors. As i have also heavily modified the looms on my TD5 I purchased quite a few of them from Eastern Beaver in Japan. They can be quite pricey though when you have stung for import duty etc. Simtek UK have a reasonable stock online and have been helpful in the past when i have wanted special order parts: https://www.simtekuk.co.uk/search.php/sumitomo Also PaulMC on here (landrover connectors on ebay) also keeps a stock of most of the common connectors and can source the others. The only connector I couldn't source that I needed was the 9-pin orange Sumitomo one on the bulkhead loom which connects to the chassis loom. I just replaced it with a grey version instead with an orange marker on it to avoid confusion when plugging in. Let me know if you need any help at all, i do have a bit of a wiring fetish! 
Cheers, Steve 02' 110 TD5 Double Cab Rebuild Thread |
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1st Jun 2020 3:17pm |
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| Shroppy Member Since: 25 Feb 2016 Location: Shropshire Posts: 866
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Thanks for the rapid response Steve! I'll check out those suppliers when I get to the plumbing/wiring stage.
My wiring skills leave much to be desired but really appreciate the the neatness of properly sorted wiring. And, I can't find a reasonably priced source for Td5 130 chassis looms so I'll have to make one! Cheers, Josh 1985 127 V8 Build Thread Series 2 109" Series 1 80" |
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1st Jun 2020 3:29pm |
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