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Hufflepuff



Member Since: 25 Oct 2014
Location: Hampshire
Posts: 568

England 2005 Defender 90 Td5 XS CSW Tonga Green

Because I like changing gear myself Razz

I understand the benefits of an auto, and have driven plenty of modern autos, but enjoy the more 'in control' feeling of using the clutch and gearstick. Just personal preference really. Plus I might get another 0.3 mpg with a manual - every little helps, this will be my only banger.

Besides which, I've already got a strengthend R380 built up by Mr Ashcroft all ready to go Smile 2005 Td5 90 XS
1989 V8 110 CSW

Post #839399 24th Jun 2020 3:47pm
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GREENI



Member Since: 22 Aug 2010
Location: staffs
Posts: 10116

United Kingdom 

Another 0.3????
I reckon more Laughing instagram @v8_scumbag

Post #839403 24th Jun 2020 3:53pm
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Hufflepuff



Member Since: 25 Oct 2014
Location: Hampshire
Posts: 568

England 2005 Defender 90 Td5 XS CSW Tonga Green

Isn't +0.3mpg about +50%? Razz 2005 Td5 90 XS
1989 V8 110 CSW

Post #839410 24th Jun 2020 4:07pm
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GREENI



Member Since: 22 Aug 2010
Location: staffs
Posts: 10116

United Kingdom 

I reckon I get single figures...I just don't care though. I know certain points in the country by how much to re-fuel there..

I know Cheltenham is £45 away and Kielder Forest is £95 away !

Porthmadog is a tank and a half.... I used to fill the 110 td5 up and get there on less than a quarter!! instagram @v8_scumbag

Post #839422 24th Jun 2020 4:36pm
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Hufflepuff



Member Since: 25 Oct 2014
Location: Hampshire
Posts: 568

England 2005 Defender 90 Td5 XS CSW Tonga Green

Ouch I hope I do a bit better than that, I'd like to see 15mpg on a run when driven steadily. Time will tell... 2005 Td5 90 XS
1989 V8 110 CSW

Post #839425 24th Jun 2020 5:00pm
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CarMan



Member Since: 29 Nov 2010
Location: Cotswolds
Posts: 1541

United Kingdom 

I think 15 is entirely realistic, but I've been out with Steve driving - enough said Laughing Rob

1993 200tdi 90 hard-top
1998 300tdi 90 soft-top
2016 2.2 XS 90 hard-top

Post #839428 24th Jun 2020 5:08pm
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Hufflepuff



Member Since: 25 Oct 2014
Location: Hampshire
Posts: 568

England 2005 Defender 90 Td5 XS CSW Tonga Green

Ah good. I was trying to calculate a 110 td5 using 1/4 tank must be around 100 miles, so 1.5 tanks on a 90 in 100 miles is... Not a lot Rolling with laughter 2005 Td5 90 XS
1989 V8 110 CSW

Post #839433 24th Jun 2020 5:17pm
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Shroppy



Member Since: 25 Feb 2016
Location: Shropshire
Posts: 567

United Kingdom 1986 Defender 130 V8 Petrol HCPU Aintree Green

I'm told mid twenties is readily achieved in a P38 running Bosch injectors and an appropriate tune. GEMS let's you run it about 15% leaner than the earlier systems (aided by the up-rated injectors) so I'm hoping for low twenties from the 130 if driven sensibly.

A friend once had a 3.5 V8 2 door classic challenge truck with a sprintex supercharger, that got 8 mpg. Rolling with laughter 1985 127 V8 Build Thread
Series 1 80"
Series 1 88" 4x2 Build Thread

Post #839556 25th Jun 2020 8:05am
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LandRoverAnorak



Member Since: 17 Jul 2011
Location: Surrey
Posts: 9612

United Kingdom 2013 Defender 110 Puma 2.2 USW Orkney Grey

My old Stage 1 V8 (3.5, de-restricted carbs) would easily be down to single figures on a cold morning Laughing Darren

110 USW BUILD THREAD - 200tdi 90 BUILD THREAD - SANKEY TRAILER THREAD - Instagram: @landroveranorak

"You came in that thing? You're braver than I thought!" - Princess Leia

Post #839561 25th Jun 2020 8:15am
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Rednaxela



Member Since: 23 Sep 2019
Location: UK
Posts: 31

United Kingdom 

How much ground have you made Hufflepuff?

Post #909351 24th Jun 2021 11:10pm
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Hufflepuff



Member Since: 25 Oct 2014
Location: Hampshire
Posts: 568

England 2005 Defender 90 Td5 XS CSW Tonga Green

Big Cry

I think that says it all. I look at these other threads where people go:

"Look, I bought, deconstructed, rebuilt, put a new engine in, test drove, painted, deconstructed, rebuild with another engine, all in two weeks!"

and then I go into the garage, where it looks pretty much the same as it did 6 months ago and carry on toiling away.


I have loads of questions to ask at the moment on cooling specifically, as I'm baffled by the cooling system on this model, but I'll make a new thread for that. Thanks for the prompting Rednaxela, its the kick I need.

As for the flywheel issue I had in this thread - its hopefully sorted now. Clutch fitted from LOF (what a refreshingly nice chap he was to deal with!) and mated up to the engine. That is now all mounted in the chassis, which itself was a saga (not sure my Richards Chassis engine mounts are bob on - one feels like its about 10mm too far forward on one side, but it fit with 'persuasion'.

Fuel tank is in (another saga), so the next jobs are:

(a) Plumb in the fuel lines
(b) Plumb in the brake lines
(c) Sort the cooling system
(d) Plug and Play the electronics, and fire her up.

I'll see if I can dig some snaps out over the weekend. 2005 Td5 90 XS
1989 V8 110 CSW

Post #909428 25th Jun 2021 3:58pm
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mikeh501



Member Since: 07 Jan 2013
Location: United Kingdom
Posts: 994

United Kingdom 1994 Defender 90 V8 Petrol SW Alpine White

Cool, congrats. Not everyone managed it in 2 weeks. I worked out today that mine took 6.5 years lol.

Post #909466 25th Jun 2021 6:57pm
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Romadog



Member Since: 07 Jul 2011
Location: Warwickshire
Posts: 1732

Wow this thread has moved quickly....had my head in some other stuff so missed it, Well done on sorting your clutch issue.......should have just got an auto been done with it.. Wink Thumbs Up

Interested to know your cooling issues???? Have you been listening to the wrong people??

Post #909486 25th Jun 2021 9:47pm
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Hufflepuff



Member Since: 25 Oct 2014
Location: Hampshire
Posts: 568

England 2005 Defender 90 Td5 XS CSW Tonga Green

To finish off a thread I started a long long time ago... Smile

A second hand GEMS flywheel turned up in the post from Roland. I suspect it had been stored outdoors for a while based on the amount of surface rust on it.


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but it has the all important reluctor in the recessed grove on the back:


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Time for a bath, I can't be having something this dirty on my pride and joy...


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The part number of the reluctor ring then became visible:


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Unfortunately the bathtub had little effect on the front surface, so it was out with Halford's finest rust converter.


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After an overnight soak, this did a little better.

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It still needed a dose of of wet-n-dry sandpapering to prepare the surface to my liking.


Time to remove the flex plate and check the fitment:


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Looking at their side profile reveals differences in where the reluctor ring sits relative to the sensor:

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This is where I got a bit confused (small brain see). Roland had said I would have to 'file the sensor down', and I couldn't understand how you could file a plastic sensor down... Embarassed

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but its clear that the auto-sensor does not reach the groove for the manual flywheel. How could filing the sensor down possible make it reach further out into the flywheel?

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My motto is quickly becoming "when in doubt, throw money at the problem", so a manual flywheel sensor was ordered. Then it became somewhat obvious what Roland has been saying about filing it down - the housing it sits in! Manual bracket on the left, auto on the right:


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At least I now had a spare sensor for the backup parts bin.

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Next problem - how to lock the flywheel in place to do the bolts up the appropriate torque? I had ordered a Td5 lock bracket from LOF clutches, reasoning that if a R380 fits a Td5, a Td5 lock bracket should work on my Rover v8? Well life it full of failure - it doesn't fit properly, although it was good enough for a bodge it job.


Click image to enlarge



Then to fit the spigot bearing, you don't want to forget that.


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Now the next head scratcher, the clutch. Keep in mind that this is the first time I've fitted one, having always left the technicalities of this job to my Father or the garage in the past. But how hard can it be?.....


Click image to enlarge



At least the clutch fits the splines of the R380, a solid start out the gate.


Click image to enlarge



Now which clutch alignment tool to use? Father's home made bad boy (left), Frost's finest 'generic' tool (right), or the proper tool for the job (centre)?


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The Frost tool was too complicated for this engineer, and the proper tool seemed quite loose in the spigot bearing, so we went with the wooden option with the tapered end.


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Pretty well aligned to my eye, but I'm sure the mating task before me would indicate otherwise.

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But first, clutch fork shinanigans. Thankfully the v8 uses a meaty cast clutch fork, so there were no concerns about the pin pushing through it. LOF provide all the consumable parts to bring it back to spec.


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... but the slave cylinder push rod length is a bit of a guess, as there at least three different sizes. After a bit of Googling, the one around 99mm seems to be most suggested to fit, so that's what we've gone with. I guess I won't find out if this was right until a lot further down the road, but it felt about right when fitting the slave cylinder.


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So, assemble the bits...

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I hope you are paying attention and see the glaring mistake here...

Click image to enlarge




If you didn't, that's ok I didn't either. Many a minute was spent trying to understand why I couldn't fit the pivot point on it.

Click image to enlarge



Ah ha... the cup has to go the other way around Embarassed

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That's better!

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Right.. one engine, one gearbox. Time to let the nature take its course, and mate them.

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Except its really quite heavy. Hoist to the rescue...

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Huff and puff, wiggle wiggle...

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and voila monsier!

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One quick check to see if the Health and Safety ministry are paying attention (nope), raise it all flip it round in the limited space and slot in.


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Progress Very Happy

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Small casualty of the right hand knock sensor when fitting Evil or Very Mad

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Next up the transfer box


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only to then find it really really tight fitting the transfer boxes mount onto the chassis mounting.


Click image to enlarge



I did get it in eventually, but it feels far tighter than it should be. Its like one of the Chassis mounts is about 10mm off. 2005 Td5 90 XS
1989 V8 110 CSW


Last edited by Hufflepuff on 26th Jun 2021 9:57pm. Edited 1 time in total

Post #909594 26th Jun 2021 9:47pm
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Hufflepuff



Member Since: 25 Oct 2014
Location: Hampshire
Posts: 568

England 2005 Defender 90 Td5 XS CSW Tonga Green

Romadog wrote:
Wow this thread has moved quickly....had my head in some other stuff so missed it, Well done on sorting your clutch issue.......should have just got an auto been done with it.. Wink Thumbs Up

Interested to know your cooling issues???? Have you been listening to the wrong people??



I'll get back to you on the cooling issue I have, run out of steam for today. I'm sure I'm just being dumb and you will point out the error of my ways in a heartbeat... 2005 Td5 90 XS
1989 V8 110 CSW

Post #909595 26th Jun 2021 9:49pm
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