Nick's Land Rover - Series III Rebuild

I have completed the rebuild of the engine.  The coking was very significant, but no lasting damage seems to have occurred.   Two new oil control rings were fitted on pistons 2 and 3, a new head gasket of the latest composite type was used, and new head bolts and breather unit were fitted.
I wanted to [...]

I took the 109 out on a few miles’ test run again yesterday to check the work undertaken before refitting the whole floor - the driver’s side floor panel was laid in loose, but the tunnel cover and passenger floor were left out just in case there was still a fault. It’s amazing how [...]

The transfer box was completed, with a check using the spring balance I bought from the fishing tackle shop for setting the front axle swivel pre-loads. Unfortunately, the pre-load is supposed to give a draw resistance on the string line of 2-4lbs, but I got a break-out force of 2lbs with a steady draw [...]

I recieved the new transfer box parts from Dunsfold Land Rover this afternoon.  This enabled me to fit the transfer box output shaft to the casing and fit the bearings.  I fitted a new thrust washer and circlip on the forward end of the shaft to replace the slightly worn washer and broken circlip (only [...]

Having rebuilt the gearbox, I’m now checking through the transfer box. Apart from weeping seals on the output shaft and a rattle from the high/low selector stick, I didn’t have any symptoms to worry about, but I’m glad I decided to check anyway.
I’m not sure if the output shaft’s rear bearing outer race slipped [...]