Outer Limits 4x4 Board

Ok made some calls today and there is a guy who specializes in re-threading. He's going to do it for $88. No need to remove the case either so im happy. He said with the case full of oil the oil dribbling out will remove most of the shavings and i'll flush the case afterwards too to remove any ...

Thanks for the reply. So you think take the WHOLE transfer case off? I was actually meaning just take the rear section of the transfer case off. The panel that has the filler/drain plugs on it. Make sense? When I was looking at it it looked like you could unscrew about 10 or so bolts and that panel ...

Hi All, I just got my gearbox and clutch all back together and tail shafts on, undid the transfer case filler plug to fill it with oil and the thread for the case came out with the bolt!!! And no the bolt was not cross threaded or anything because the thread on it is perfect. Why this happened isnt ...

Well that explains why I had to replace the rocker cover! Thanks! The front corner on the passenger side had a crack through it...no doubt from the broken engine mount!

Anything else I should look for while im at it?

Well I got the mounts changed. I did both sides. The passengers side was broken so Im glad I did it! The drivers side wasnt but changed it anyway. Will keep the old one of that as a spare. But did anyone else find that the passenger side one didnt line up to the bolt holes after changing it? I had ...

Thanks for that. Makes a lot of sense really. Any tips on undoing the bolts for the drivers side mount? I bought a drivers side one too cause I was told it was too soft so id like to change it but getting access to it isnt easy.

Any chance someone can post pics of the mounts with the seatbelt wrapped around?

Ok well i've got the engine and gearbox mounts put away for me and also a clutch fork. Can someone please point out which part this is? Apparently it is common for these to break in Roza's.

Also, why should I wrap the mounts in webbing? How many layers? And should I do all three?

Cheers
Ben

Thats a very good point! As painful as it is having to redo it each time its much better than something else more important breaking. I will stick to the usual high tensile bolt and replace the mounts and arm mechanism. Hopefully Daihatsu have some mounts I can use this weekend! The bolt usually has ...

Thats true but still no guarantee it wont happen. Its already high tensile and shouldnt be happening. What gets me is that is seems like im the only one who has experienced this problem? Perhaps when I pull the box out I will go to the Daihatsu wreckers and get another arm etc. At this point this I ...

Yes I replaced that the first time it started happening as I thought it was the cable stretching. Is there any chance worn/soft gearbox and engine mounts would cause this? Im thinking outside the square here but would the movement from the engine/gearbox put undue stress on the bolt while the clutch ...

Ok folks...I'm having to resurrect this post again! Over the past week the shifting is getting worse. First is almost impossible to get. So most time i'll turn the engine off, shift into first and then start it up. I need help! What could be doing this??? The clutch has always engaged in the last ...

Ferozamaniac: No there wasnt any weird noise either time it happened. The symptoms are not being able to find gears easily and it gradually (or quickly) gets worse. After tightening the cable it is fine and then goes back to being difficult. Of course the first thing you'd check is that the nut for ...

Ok think I found the problem...as I was undoing the bolt the bottom half of it snapped off and the top half of the bolt was about to snap. Looked at the thread inside the clutch release fork lever and the top half of it was all smooth! So the bolt was only threaded into the bottom half and therefore ...

Ferozamaniac: The grover you are talking about is it the one that bends up at the front and prevents the bolt from undoing? If it is then it already has one and is doing its job fine. You have to somehow bend it back down in order to undo the bolt. On closer inspection of the bolt I think it ...

I bought Rhino (supporting Aussie made) and I have had no end of trouble! The front rack that attaches to the gutter keeps wanting to work its way out and only holds on by about 1mm. So I contacted the rep and he tried a few things and ended up saying that they recently redesigned the front clamps ...

I assume this is the clutch fork? Doesnt look to be bent to me. Look ok to you? Im at a loss now. I hope I havent pulled the gearbox out for no reason! Any more ideas anyone? I need to get this fixed today as I need it for work and have taken the day off to fix it... http://i199.photobucket.com ...

Thanks for the help! Much appreciated. Ok here are the pics...I hope this works!

Ok I dont know how to put pics up. Can someone tell me?

Hi All, About 2 years ago (on the eve of a camping trip) the bolt inside the bellhousing that connects the clutch arm shaft to the thrower bearing snapped. It sheared off completely at both ends. So I pulled the gearbox out and replaced the bolt with a new high-tensile one. This week I am having ...

Ok guys I got the new resistor pack for $31.85 from Motorama and it slots straight in and I have all 4 fan speeds again! Woo hoo! Finally getting things straightened out in my rig. It took all of 5 mins to take the glovebox off, plug the connector in, screw the resistor pack in, put the glovebox ...

The resistor pack is a set of three wires coiled to look a bit like what the old light bulb coils looked like. The wires sit on a black plastic bracket about 1.5" x 1" but in a diamond shape. Its easy to find. All I did was phone up Motorama at Moorooka (yes they are a Daihatsu dealer) and asked ...

Mine is stuffed too. So I removed the resistor pack on the weekend and brought it into work with me and phoned up Motorama for a new one. $31.85 and in stock. So I will be picking that up on the weekend. Will be good to have the fan on without it going flat strap! :) PS. Removing it is dead easy ...

Yeah Its all good now. Thanks though. Had to wait til Thursday to get them as Super Cheap stuffed up my order. But for everyone else's reference Super Cheap were the cheapest out of everyone.

Cheers
Ben

Hi Everyone, Well I just pulled the rear wheels off as my brake light has come on (the fluid level is low) and found that the rear left wheel cylinder is leaking fluid! Havent taken the right hand wheel off yet but I'd probably guess it is too. I have rung around all the stores today and no one has ...

Man I would love to know more about this cause Ive been thinking of doing it for ages but dont know how or where to start. Any info would help!

I'd be up for this!! Depending on price of course...

Nice pics of the Fez Brad! What setup have you got for the suspension and wheels/tyres?

ben

I was at a tyre place in Slacks Creek not long ago and he had 30" Triangle AT's for $120 a corner brand new. I've never heard of them before but I had a look and they looked pretty good. Prob not as aggressive as some other more popular brands but for the price I was impressed! Does brand really ...

Yep araldite both items up! i did and im not getting high anymore.