With no curling this weekend, I really dove into the Disco. Today is a month even to go, and it’s starting to feel a bit real. I’m leaving on the 20th, and it was the 20th today.
Thus the pace quickens. I’d like to do some kind of test run at least two weekends before. I’m considering two Rover events — one in Quebec, one in Virginia — and a few more likely ~600 mile weekend runs. I may tinker with the National Park Service unit map and see if I can plot out how to knock off a few new ones in a weekend trip, especially because doing things like that regularly in this truck is part of the goal of this project.
I decided the primary goal this weekend was to remove the old transfer case, transfer the necessary items to the new transfer case, and get the new transfer case fully assembled and sealed with the combined components. This was partially accomplished within the traditional bounds of “the weekend.” So, into the garage Duncan went again, for at least a week of driveline surgery.
First, it was time to drop the exhaust, and this is where I found out that my exhaust patch from a few weeks ago was, in fact, the snake oil I thought it was. I figured this had probably happened when I drove on the Interstate for the first time and it got very noticably louder, but a visual confirmed it.
And so disassembly began. First I dropped the swaybar to allow the Y-pipe to come out, then once the exhaust was down (easy as I’d already undone all the problem fasteners a few weeks ago), it was on to one of my least favourite jobs on a Rover, disconnecting propshafts. Thanks to the one tool that every Land Rover owner should have, it was way easier than it could be, but still took almost an hour to do both. Finally, they were both down, the necessary bolts retained, and it was onward.
Thanks to the modification I did last year to the centre console, replacing the rivets holding the covers for the transmission and transfer case shifters in place with rivnuts and screws, I made quick work of exposing the shift linkage. I was happy to see the lithium grease in the shifter pivot assembly somewhat holding up after a year, though I will renew it when I put this all back together, and pack in a bit more overflow!
Next was the centre removable crossmember under the transmission. This can be a notorious right royal PITA. It took me about 45 minutes to get the eight bolts off, and I had to cut one off with the die grinder, so I guess I should figure out what size that was and call up McMaster Carr. Then it was some smacks with the sledgehammer, spread the frame with the Big Red hydraulic ram, and it came off, to expose this horrifying sight underneath. Certainly the truck will already require some welding when I get home, but since this is covered with the crossmember, which bridges this hole and inherently stabilises it, I’m going to pretend it isn’t there until the Summer of Bodywork commences on arrival at home.
The final act of Saturday was pulling the handbrake drum off the back and removing the rear output flange; it’s quite frankly nicer than the one on the Q box, so I’ll probably reuse it (especially as it has nice zinc coated Grade 8 bolts that I put on!). At this point, I started to see just how grimy thousands of miles of gear oil spraying everywhere can be. On the plus side, this must have helped to mitigate some rust that otherwise might have been. After everything’s together (by which time the string of Nor’Easters hitting us “should” have stopped), I’ll powerwash it all heavily.
I tucked it in for Saturday, got to bed at midnight, and planned a continuation of activities for Sunday. The Fitzgerald family had tacos for dinner on St. Patrick’s Day, having realised after decades that we don’t really love corned beef and cabbage.
Sunday it was back to work, and time to disconnect the box. I undid the shifter linkage completely, removed the input gears, loosened all of the bolts securing the transfer box to the transmission, and detached the transfer case mount bracket from the chassis. At this point, I looked at all of this and decided that I am a man of little upper body strength, and perhaps it might be worth it to pony up for a transmission jack, instead of using what my friend Rob called “the sea otter procedure.” So, it was off to Harbor Freight, land of cheap tools that might kill you, but you’re only using them once so you’ll take the risk to save a few bucks. Forty-five minutes later, I returned from Harbor Freight (the former Saturn of Green Brook, with the service department hours still posted on the side door) with a lighter wallet and the relative guarantee I wouldn’t be tapping my ER deductible for caving my chest in.
I detached everything, and had my dad come and supervise from the top while I wiggled the case off the bolts. This went great until I hung up on the stud on the top right. In retrospect, I should have removed the rubber transfer case mount and its bracket from the case, as I ended up wedging it against the chassis. But it was getting late, I was wiped, and I had laid waste to my body today, so I washed up and left it for later.
Monday I went to the office, and had a bit of discomfort with some more repetitive copy-paste coding things, having wrecked my hand over the weekend. I got home late and couldn’t get too much on the truck, unfortunately.
But I was pretty excited, because my bulk pack of Powerspark Red distriutor rotors came from England. The current crop of Genuine Land Rover distributor rotors is, in a word, crap, so this company has stepped in with an aftermarket replacement. I personally don’t need them right now, but I’ll carry them with me across, as a few Mendonites are looking to tinker with ignition issues and have called dibs. They have had some good reviews with their earlier products for other British marques.
Tuesday, I decided that I needed to motivate myself more to get this done, so into the garage again. I decided that part of my alignment issue was that I was trying to drag the case out with the rubber mount and bracket dragging on the chassis. But…I was in a Catch-22, because the nuts for the mount had been on there for a while, and were attached to a very flexible bit of rubber, keeping me from being able to apply the necessary torque to liberate them.
The transmission jack was helpful, but the transfer box is mounted at an angle, so it didn’t totally fit on the flat jack plate. The service manual directed the dealership to fabricate an elaborate, angeled bracket to remove them, but I can’t weld yet, and I don’t think it’d mate to my jack, so my dad and I fabbed something up on his pre-WWII Walker-Turner table saw.
I took this outside, but it didn’t help. Finally, I felt the energy of despair and rage build me and I gave a Herculian shove as my dad stood above through the hatch prising the case from the transmission. And then, we were free of the input shaft, and I lowered the old case in glory!
With the driveshafts, transfer case, and exhaust gone, there’s so much space for activities!
Now to the next step: finishing the build of the new Q box. I now have the old box down and can pillage everyhing I need from it. I started tidying the mating surfaces with 400-grit wet/dry sandpaper and brake cleaner. Tomorrow, assuming the latest Nor’Easter doesn’t send us back into refuge across town at our friend’s house, I’ll start sealing it up.
Saturday, 17 March: Donna the Buffalo, Live from the American Ballroom; Skinny Lister, Forge & Flagon; N.W.A., Straight Outta Compton.
Sunday, 18 March: Culture Club, Colour by Numbers; Elton John, Too Low for Zero.
Tuesday, 20 March: Billy Joel, The Stranger