Nick's Land Rover - Series III Rebuild

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 [...]

Most of this task went easily enough, though removing the Wright Off Road matting adds a small amount of extra effort. The floor panels, tunnel cover, prop shafts, hand brake rods, speedo cable and bell housing bolts were al removed as normal, and the Roverdrive was separated to allow space for the gearbox assembly [...]