Axle Removal

Finally got back to working on the 90 this weekend, and made a start at removing the axles ready for restoration. Front axle was first, and managed to get removed by the end of saturday. Radius arm bolts seemed to be corroded is place, and had to be cut out. After cutting the remaining connections to the chassis, the axle rolled out easy. Will be looking for replacement radius arms at either paddocks or the Driffield show.

Sunday involved removal of the rear axle. Managed to get all the bolts undone on the trailing arms, after a lot of efford, and also from the a-frame. Found that a large tyre lever was just the tool for removing the bolts from the A-Frame.

Next I rescued the toll ball/pin from the rear X-member, which required a bit of grinding. Also cut off the ends of the cross member (which were completely rotten), ready for replacing with the new cross member.

Then will the axles removed, the chassis was moved over the side of the drive, put on stands and covered up in tarp. Got next week off work, when I will hopefully be doing all the work on the chassis - Stripping, cutting, welding & painting.

Last job of the weekend - stripping down the axles. Started on the rear axle - removing trailing arms, shocks and a-frame. Lots more mud fell on the garage floor - seems to be a never ending supply of the stuff.

Springs have started to be cleaned up. These at least are in reusable condition.

On the front axle, the panard rod has been removed, along with the springs. Was started to get a bit late, so decided to leave the shocks, radius arms and drag link to another night this week.

Engine & Gearbox Rebuild

Started to rebuild the block over the weekend, once all the parts had arrived. First job was putting new pistons rings into the pistons, then putting the pistons back into the block.

Cleaned up the sump tank, and painted it in black gloss polyurethane. After refitting the oil pump (with new gasket) the sump was refitted, with new sump gasket.

The head is currently being cleaned up ready for refitting. But as can be seen in the first photo, the head has a lot of carbon on it, so some overnight soaking will hopefully loosen off the worst of the coke build up.

I've now made the decision that this engine will only be used temporarily. Once the truck is on the road again I'll be looking for a 200TDI to replace the 2.25.

The gearbox and new transfer box have been attached now. I've decided to keep the disco box for now, knowing that I'll be upgrading to a TDI in the near future. I can cope with it being slow on road, as this will be mainly used off road anyway.

I also started practicing my MIG Welding on Sunday evening, ready for when I need to do the chassis repairs. Quite confident that after a little practice, the chassis welding won't be a problem.

Went shopping at Paddocks on Saturday morning too - and spent a large sum of money. Got new polybush kit, all new brake parts for each corner, swival ball kit, etc. Also went to the local scrapyard to get an electric fan to replace the viscous fan. At £5 much cheaper than getting a kenlowe.

Engine & Gearbox Cleaning

Final job of the long weekend was cleaning up the engine and gearbox a bit more.

Main effort was spent getting the main gearbox cleaned up ready for fitting to the replacment transfer box.

Need to order new gaskets, bearing shells & piston rings for the engine, then once the head has been cleaned up, the engine can be reassembled.

Shopping @ Sodbury

Went shopping on Saturday, at Sodbury for various parts required for the 90. Got most of the parts I really needed, plus a few that I didn't intend to buy. Managed to spend a large some of money anyway - which is listed below for my own benifit later when I finish the project and work out how much its cost me.

Below is a list of the parts that I got on Saturday and further down the photo's of everything.

• Brand New Front Propshaft - £20
• Galvanised Jackable Rock Sliders - £75
• Front Grill - £10
• Front Light Surronds - £5 each
• LT230 Transfer Box from Disco - £100
• Water Pump - £10
• Rear Steps - £25 for pair
• Gloss Black Polyurethane Paint - £10each x 2 tins
• Airplane Blue Polyurethane Paint - £11each x 3 tins
• Heavy Duty Galvanised Front Turrets - £35 for pair
• Heavy Duty Turret retaining rings - £12 for pair
• Rear Dislocation Cones - £30 for pair
• Gear Stick Gaiter - £3.50
• New Wheel Nuts - £0.50 each x 21
• Gas Shock Absorbers Set of 4 - £150

Gearbox Removal

Now the enine has been removed, the gearbox is also removed, for a cleanup & to fix the stuck high/low gear stick. At Sodybury I'll be keeping an eye out for a replacment selector shaft, or failing that a new transfer box.