 | Home > Td5 > Mid Crossmember replacement |
 
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| rallysteve Member Since: 10 Feb 2014 Location: Cumbria Posts: 2227   
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Did mine easy enough through the rear floor. Cut the old one in half to removed then the new one can be pushed into place just being careful not to damage the plastic fuel lines. I did not remove the side panels.
Steve 02' 110 TD5 Double Cab Rebuild Thread |
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12th Oct 2020 2:52pm |
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| Mdm Member Since: 11 Sep 2013 Location: Sunny Lancashire Posts: 1599
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side panels and rear floor removal make it easy and you can remove al the mud from under there and paint and waxoyl the hard to reach areas
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12th Oct 2020 3:04pm |
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| lightning Member Since: 23 Apr 2009 Location: High Peak, Derbyshire Posts: 2769
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l did mine last month.
You need to remove the seats and rear floor. The old crossmember can be cut in half but you won't be able to do it with a hacksaw due to access issues, you'll need an angle grinder. l actually ended up cutting both ends off mine as it was easier to get to.  Click image to enlarge On my 2005 110 there were two brackets on the top of the chassis, which prevented the new crossmember from sliding into place. These brackets are for the truck cab version so can be cut off. Two of the bolts holding the mid crossmember to the chassis need cutting off as you can't get them out, but an option is to drill two holes at the rear of the floor (once the floor panel is out) and then the bolts will come out. Note that the body will drop slightly (around 5mm) when the mid crossmember is removed, and you will need to jack it up in order to fit the brackets on the new crossmember. Picture shows the unused brackets, you need to cut the rear part of these diagonally in order to slide the new crossmember into place. And also to get the old one out if you've cut the ends off it. Click image to enlarge |
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12th Oct 2020 9:08pm |
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| Intercept Member Since: 27 Feb 2017 Location: Suffolk Posts: 587 
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See https://www.defender2.net/forum/topic70049.html for more pics and info. I didn't remove the side panels.
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13th Oct 2020 10:33am |
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| lightning Member Since: 23 Apr 2009 Location: High Peak, Derbyshire Posts: 2769
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Agreed, no need to remove the side panels
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13th Oct 2020 9:27pm |
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| Suki Member Since: 12 Oct 2020 Location: Essen Posts: 3  
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Click image to enlarge thanks for your help guys |
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15th Oct 2020 9:55am |
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| Intercept Member Since: 27 Feb 2017 Location: Suffolk Posts: 587
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^^^ that's a familiar sight. Glad to hear that you've got the old one out. Putting the new one back is much easier
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15th Oct 2020 11:39am |
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