 | Home > Td5 > TD5 90 rear X member replacement |
 
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| jrule Member Since: 10 Aug 2015 Location: Hertfordshire Posts: 302   
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You can do without removing the tub although is a bit of a pig of a job especially if bolts corroded. You have to remove anti roll bar and tank guard and then should be able to manoeuvre the tank out. The tank guard has fixing nuts in the rear cross member and also to chassis legs from memory. It is easier if you have access from above and often people cut out an access panel to the fuel pump so you can disconnect loom and lines more easily.
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19th May 2020 7:27pm |
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| jrule Member Since: 10 Aug 2015 Location: Hertfordshire Posts: 302
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This is quite helpful for guard removal
https://yrmit.co.uk/workshops/land-rover-d...placement/ |
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19th May 2020 7:30pm |
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| dorsetsmith Member Since: 30 Oct 2011 Location: South West Posts: 4554 |
now that makes a lot sens,fitting and bolt it up from out side
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20th May 2020 1:49pm |
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| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4784 
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I have dropped my tank recently. It's very tight and awkward but it slides forward towards the axle then half way down before you can remove the pipes and plugs
 2002 90 Td5 Station Wagon
1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton |
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20th May 2020 4:54pm |
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| dorsetsmith Member Since: 30 Oct 2011 Location: South West Posts: 4554 |
manage to remover fuel tank cradle but cut one side and will remove captive nut and nut bolt back in place
next thing remove tank very tight and awkward its five o'clock and time pint or two |
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20th May 2020 5:30pm |
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| grafty99 Member Since: 15 Aug 2012 Location: North Devon Posts: 4784
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2002 90 Td5 Station Wagon
1990 Vogue SE Triumph Tiger Explorer 1200 Td5 90 Thread http://www.defender2.net/forum/topic50767.html Tdi 110 Thread https://www.defender2.net/forum/topic69562.html RRC Thread http://www.defender2.net/forum/topic54492.html Instagram http://www.instagram.com/george_grafton |
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20th May 2020 6:13pm |
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| dorsetsmith Member Since: 30 Oct 2011 Location: South West Posts: 4554 |
tank out in three moves
new hoses order for tank vent 6 mm 1/2 m long and 3/4 1/2 m long next have look at loom from the N side rear O that`s not good out with box wire split conduit and tools 2 hr later this pasty o clock 89 F time for brake |
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21st May 2020 2:24pm |
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| lightning Member Since: 23 Apr 2009 Location: High Peak, Derbyshire Posts: 2222
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Thirty one years old so it’s not done badly.
And l bet it’s worked hard for many of those years as well. An ordinary van would have been scrapped twenty years ago. |
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21st May 2020 4:03pm |
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| dorsetsmith Member Since: 30 Oct 2011 Location: South West Posts: 4554 |
up date has been bit slow to date as needed more work to rebuild both chassis leg so that i can use the new cross member that i have will post pic late to day work in progress
 Click image to enlarge Click image to enlarge as you can see metal moth has been at it Click image to enlarge Click image to enlarge will have to make two ^ chassis box section work in progress |
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30th May 2020 7:44am |
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| jst Member Since: 14 Jan 2008 Location: Taunton Posts: 7681 
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That going to take a few hours to sort! No legs on replacement cross member then? Cheers
James 110 XS Utility 130 Puma Station wagon/camper (in the making) 90 Puma Hardtop |
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30th May 2020 7:27pm |
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| dorsetsmith Member Since: 30 Oct 2011 Location: South West Posts: 4554 |
no and good job to had to faecal both sides to work with ware metal moth had made holes in the chasse legs
Last edited by dorsetsmith on 17th Oct 2020 1:41pm. Edited 1 time in total |
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30th May 2020 7:38pm |
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| Oldowner Member Since: 26 Dec 2018 Location: South west Posts: 601 
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Well done, I didn’t think anyone else replaces the cross member the proper way without resorting to “crossmember with extensions” bodgery
I had a supply of the triangular closing plates in one of your photos from the manufacturer at one point as these are unavailable to purchase separately. |
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30th May 2020 8:39pm |
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| dorsetsmith Member Since: 30 Oct 2011 Location: South West Posts: 4554 |
that right now priced £ 200 a side but out stock will be making the replacement ones
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30th May 2020 8:46pm |
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| Dinnu Member Since: 24 Dec 2019 Location: Lija Posts: 3183  
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Did a crossmember replacement for a friend. Decided to take the tub off, as the top was coming off anyway to attend to the cappings. With the tub off, access is much better. He had purchased KVB000290G from Paddock, that comes without legs.
Indeed, I could not find the top webs between the cross member and the chassis rails, so those were made inhouse from a 2mm sheet. templates were taken to copy the folds and holes locations. Similarly, there are 2 trapezoidal plates at the bottom just between the chassis rails and the crossmember. These are welded in flat and then the edges hammered around the chassis before completing the weld. Measurements for the crossmember location were taken relative to the tub support bracket and A frame crossmember. If i had to do it again (hope not as it is a pig of a job) i would do as much welding as possible with the fuel tank cradle in place and fully tightened, as after i finished, I found that the cradle holes did not align perfectly with the holes next to the roll bar brackets. Holes at crossmember however aligned perfectly. Not sure if the welding distorted a bit the rails, or the sanblasting and galvanizing of the cradle warped the cradle. End result was very satisfying though. Not possible to detect that the crossmember was ever replaced as all factory welds were re done. 1988 90 Hard Top, 19J Diesel Turbo, Shire Blue - Restoration ongoing 2012 90 CSW, 2.2TDCI, Santorini Black |
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30th May 2020 9:38pm |
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