Gearbox next. As usual, I will flip it over to get to the sump and filter, however normally when I do that the diffs are drained ready for re-sealing. This one though is not leaking and so I'm not touching the output flanges and not draining the diffs. That means that if I flip it over, the gear oil will all leak out of these breather holes:

http://forum.a8parts.co.uk/attachmen...1&d=1622148471

So, I printed some polyurethane plugs for them which worked very nicely

http://forum.a8parts.co.uk/attachmen...1&d=1622148471

The ATF is nice and clean

http://forum.a8parts.co.uk/attachmen...1&d=1622148471

I flipped it over to remove the sump. This bolt was stuck and stripped out. I cut a slot in it with the grinder and then persuaded it loose with a cold chise. There are usually a couple stuck on this side because the holes here go right through and the end of the threads get rusty. I have plenty of spare bolts so not a problem.

http://forum.a8parts.co.uk/attachmen...1&d=1622148471

Stuck bolt at the top with crusty threads. All the other bolts were nice and clean.

http://forum.a8parts.co.uk/attachmen...1&d=1622148471

Nice and clean in the sump - no fluff on the magnets. The phone had considerable trouble focusing on the shiny surface.

http://forum.a8parts.co.uk/attachmen...1&d=1622148471

Evidence of a leak on this corner

http://forum.a8parts.co.uk/attachmen...1&d=1622148471

Left it overnight to drain. New filter and sump back on tomorrow

http://forum.a8parts.co.uk/attachmen...1&d=1622148471

looking good, hows the F125 test?

Not opened it up yet - thats another job for today +++

BTW meant to ask, what condition are the rads in?

Not inspected them up close, but I didn't see any problems when I took the front panel off.

Finished off the gearbox and completely forgot to take any photos :tuttut: New filter and gasket, cleaned the sump, primed the pump - the usual drill.

At Mark's request I dismantled and inspected the F125 while it was easy to get to - nothing unusual to report and everything ship-shape so I re-greased it and bolted it back together.

http://forum.a8parts.co.uk/attachmen...1&d=1622231966

Contacts are all good

http://forum.a8parts.co.uk/attachmen...1&d=1622231966

Gearbox reassembled and back on the separating table for, er, 'un-separating' tomorrow :D

http://forum.a8parts.co.uk/attachmen...1&d=1622231966

Once the engine and box are bolted back together I can spin the engine on the starter to get oil pressure, and then put the wiring harness back on.

What state were the original tensioner pads like on this MJ?

On one of the pics they look new so I’m assuming you replaced them as part of the process.

They were actually pretty good - minimal tramlining, but someone had definitely been in there before so they may have been changed previously. I put new ones in anyway since it was all apart.

Another slightly frustrating weekend of back pain and breakdowns, but I made some good progress today.

I have built a magic box to simplify the process of spinning the engine to get oil pressure while its on the separating table. It plugs in to the oil pressure switch, has a couple of flying leads to connect to a battery, and the starter cables attach to the right hand side. The red button is a switch which lights up when it has power

http://forum.a8parts.co.uk/attachmen...1&d=1622490389

Press the switch to activate the starter, and the green light comes on when there is oil pressure +++

http://forum.a8parts.co.uk/attachmen...1&d=1622490389

5 litres of fresh oil in to the gearbox (6 in total - 1 litre went in to the pump when it was upside down)

http://forum.a8parts.co.uk/attachmen...1&d=1622490389

Took the engine and box off the separating table and put them back on the subframe to refit everything else. Spark plugs and coil packs on.

http://forum.a8parts.co.uk/attachmen...1&d=1622490389

I'm swapping the engine harness (because of the missing connectors) and so I need to swap over the ECU, but first it needs breaking out of its jail

http://forum.a8parts.co.uk/attachmen...1&d=1622490389

Cut slots in the shear bolts so they can be removed with a screwdriver

http://forum.a8parts.co.uk/attachmen...1&d=1622490389

Escaped!

http://forum.a8parts.co.uk/attachmen...1&d=1622490389

The replacement harness

http://forum.a8parts.co.uk/attachmen...1&d=1622490389

Fitted to the engine

http://forum.a8parts.co.uk/attachmen...1&d=1622490389

New coolant hoses

http://forum.a8parts.co.uk/attachmen...1&d=1622490389

New O2 sensors as well

http://forum.a8parts.co.uk/attachmen...1&d=1622490389

The engine and box are finally complete, at long last. As I'm replacing the control arms, I'll attach the lower arms and driveshafts to this tomorrow which will make it much easier to put back together.

http://forum.a8parts.co.uk/attachmen...1&d=1622490389

That engine looks MASSIVE & really impressive seeing you get in there! 👍👍