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Joncorry



Member Since: 03 Apr 2022
Location: Cheshire
Posts: 167

 2003 Defender 110 Td5 G4 Challenge Tangiers Orange
The MOT was booked for today. On Friday, the steering box seal decided it no longer wanted to seal.

Not the worst job I’ve done and made easier with a Rimmer Bros how to video but it’s an little awkward to remove. I ordered a replacement from SP 4x4 which hopefully should arrive today.
The old steering box (a Dura Automotive item) was still operating fine so I assume can be reconditioned and kept as a spare or I might sell it on.

The new Terrafirma steering arms are going on along with a new steering damper so it should look a bit prettier for the MOT tester!



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Fingers crossed it goes back together nicely! 2003 110 G4 used in 03 and 06 events - its well travelled.
2002 Range Rover G4 Event car (Australian leg)
2008 Discovery 3 G4 UK Selections car
1968 Series 2a
Post #1025279 20th Feb 2024 9:03am
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Joncorry



Member Since: 03 Apr 2022
Location: Cheshire
Posts: 167

 2003 Defender 110 Td5 G4 Challenge Tangiers Orange
The new steering box arrived from SP 4x4 today. Not bad, sadly made in china and comes without a new drop arm nut and washer. The smaller (metal) power steering line also needs some gentle fettling to make it reach the new position on the new steering box, its now miles but by no means a direct fit.

I forgot to order new bolts that go through the chassis so a YRM fitting kit is one the way from LR Parts, hopefully that arrives tomorrow or Thursday.

I also need a socket to correctly torque the drop arm nut which I believe is 176NM.

So, progress but not done. 2003 110 G4 used in 03 and 06 events - its well travelled.
2002 Range Rover G4 Event car (Australian leg)
2008 Discovery 3 G4 UK Selections car
1968 Series 2a
Post #1025326 20th Feb 2024 2:44pm
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Joncorry



Member Since: 03 Apr 2022
Location: Cheshire
Posts: 167

 2003 Defender 110 Td5 G4 Challenge Tangiers Orange
Very slow painful progress not helped by the pump to box pipe not fitting… apparently the pipe will bend to fit….



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New arms and damper fitted ok.


Click image to enlarge
 2003 110 G4 used in 03 and 06 events - its well travelled.
2002 Range Rover G4 Event car (Australian leg)
2008 Discovery 3 G4 UK Selections car
1968 Series 2a
Post #1025516 21st Feb 2024 6:28pm
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Screbble



Member Since: 26 Apr 2015
Location: Lancashire
Posts: 2102

United Kingdom 2004 Defender 90 Td5 XS CSW Zambezi Silver
Looks Superbulous 👍
Post #1025519 21st Feb 2024 6:34pm
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Joncorry



Member Since: 03 Apr 2022
Location: Cheshire
Posts: 167

 2003 Defender 110 Td5 G4 Challenge Tangiers Orange
Whilst the Defender awaits the work to complete on my Discovery so it can have the manifold sorted, I’ve done a few things with it. The MOT was a clean pass thankfully so I treated it to a more modern head unit that has car play etc… it’s more for Nav than sound as the speakers are a bit rubbish and my ears aren’t mounted on my shins.
It fits neatly and doesn’t interfere with the gear change although a short shift would probably mitigate that even more. Very pleased with it on the whole.



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 2003 110 G4 used in 03 and 06 events - its well travelled.
2002 Range Rover G4 Event car (Australian leg)
2008 Discovery 3 G4 UK Selections car
1968 Series 2a
Post #1027774 12th Mar 2024 10:27am
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LJMARSDEN



Member Since: 08 Jun 2021
Location: Nottingham
Posts: 338

United Kingdom 2006 Defender 90 Other HT Java Black
that will give my OCD some grief... Rolling with laughter

This was my solution for apple carplay.


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Slightly larger screen than a single din @ 70mm while single din is 52. 4.0 V8 Defender 90

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Post #1027777 12th Mar 2024 10:49am
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Joncorry



Member Since: 03 Apr 2022
Location: Cheshire
Posts: 167

 2003 Defender 110 Td5 G4 Challenge Tangiers Orange
That’s neat.

Your ocd would love the electric window switches, press up to lower on the drivers side and down to raise and the passenger side doesn’t work 😄

The steering wheel was about 38 degrees off after I replaced the steering box so I made a tool to remove the wheel.



Click image to enlarge


It’s now straight..ish 2003 110 G4 used in 03 and 06 events - its well travelled.
2002 Range Rover G4 Event car (Australian leg)
2008 Discovery 3 G4 UK Selections car
1968 Series 2a
Post #1027782 12th Mar 2024 11:30am
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LJMARSDEN



Member Since: 08 Jun 2021
Location: Nottingham
Posts: 338

United Kingdom 2006 Defender 90 Other HT Java Black
bloody hell I'd end up driving into a ditch, deliberately Rolling with laughter

have you had chance to test the steering since the refresh - should be quite the improvement 4.0 V8 Defender 90

My Instagram
Post #1028451 18th Mar 2024 10:38am
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Joncorry



Member Since: 03 Apr 2022
Location: Cheshire
Posts: 167

 2003 Defender 110 Td5 G4 Challenge Tangiers Orange
I’ve not put a huge amount of miles on since all the steering work but those I have driven are better than before. It’s a bit less ponderous, not perfect by any means but better. 2003 110 G4 used in 03 and 06 events - its well travelled.
2002 Range Rover G4 Event car (Australian leg)
2008 Discovery 3 G4 UK Selections car
1968 Series 2a
Post #1028471 18th Mar 2024 12:26pm
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LJMARSDEN



Member Since: 08 Jun 2021
Location: Nottingham
Posts: 338

United Kingdom 2006 Defender 90 Other HT Java Black
worth the time then, also its job off of the list Thumbs Up 4.0 V8 Defender 90

My Instagram
Post #1028480 18th Mar 2024 1:41pm
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Joncorry



Member Since: 03 Apr 2022
Location: Cheshire
Posts: 167

 2003 Defender 110 Td5 G4 Challenge Tangiers Orange
I dropped the Defner off at the local specialist for the warped manifold to be de-webbed and skimmed.
They’re good guys and spot stuff that I don’t, in this case collapsed near side swivel bearings! Another job for the list 😊 it might even drive straight afterwards! 2003 110 G4 used in 03 and 06 events - its well travelled.
2002 Range Rover G4 Event car (Australian leg)
2008 Discovery 3 G4 UK Selections car
1968 Series 2a
Post #1031481 14th Apr 2024 7:21am
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Joncorry



Member Since: 03 Apr 2022
Location: Cheshire
Posts: 167

 2003 Defender 110 Td5 G4 Challenge Tangiers Orange
Got a nice pic from the garage today, they’ve been busy helicoiling and fitting new studs to the head before the skimmed and de-webbed manifold can go back on.
New aux belt going on too.


Click image to enlarge


I also heard the n/s swivel bearings are shot so I’ve got a swivel rebuild kit as there’s some good YouTube videos on how to sort it! 2003 110 G4 used in 03 and 06 events - its well travelled.
2002 Range Rover G4 Event car (Australian leg)
2008 Discovery 3 G4 UK Selections car
1968 Series 2a
Post #1031917 17th Apr 2024 7:34pm
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L110CDL



Member Since: 31 Oct 2015
Location: Devon
Posts: 10756

England 
Moving forward there nicely on the G4 Thumbs Up 1996 Golf Blue 300Tdi 110 Pick up.

Keeper.

Clayton.
Post #1031922 17th Apr 2024 8:04pm
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geobloke



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

United Kingdom 
Ooo I have to get Miffy's manifold skimmed, you have just reminded me. Just a thought... Whilst you are there and all Rolling Eyes That threaded core plug behind the manifold, it would be worth replacing that as it looks original. They are known to leak and you have to take the manifold off to replace them.

Part Number: LCM100170G Thumbs Up
Post #1032035 18th Apr 2024 4:41pm
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Joncorry



Member Since: 03 Apr 2022
Location: Cheshire
Posts: 167

 2003 Defender 110 Td5 G4 Challenge Tangiers Orange
Thanks geobloke, core plug was sorted by the garage whilst it was apart.

All three amigos together again, Defender driving lovely apart for the swivel bearings but the kit has arrived for that.



Click image to enlarge
 2003 110 G4 used in 03 and 06 events - its well travelled.
2002 Range Rover G4 Event car (Australian leg)
2008 Discovery 3 G4 UK Selections car
1968 Series 2a
Post #1032205 20th Apr 2024 7:20am
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