New Jimny project - a few questions!

That's pretty much what I did - except, it's possible the torque converter slid out a little and mis-aligned as I was jiggling it in to place.

Tomorrow I'm going to take it out and make sure it's aligned then put it in place more carefully.

The issue with LR boxes is more often knackering the oil seal - but I dare say the oils pump could fall victim too!

Thanks for the advice though.

Si

You don't hang about Simon!

Ok, auto in and seems to line up OK - but I just cannot get the B****y starter motor back in! Because it's now 10mm further out, my hands simply don't fit in the space.

I'm looking at more radical solutions now. No1 is to remove the inlet manifold. Unfortunately, it looks even harder than the starter motor with a row of bolts below the ports that I see no way of getting a socket on without removing the engine. Any tips?

If I remove the engine, the job should be easier - but I don't really want to go there.

Removing the front axle is a possible.

Has anyone cut a big hole in the inner wing to give access?

Any ideas much appreciated! I've got to the point of wondering how big a trebujet I'd need to throw it as far as the tip 1/2 mile away!

Si

I had the same problem with the starter motor just could not get to it, after trying every different way of getting my arm up to it i got fed up and just cut a hole in the inner wing and it was then really easy.

The solution!
Stop and have a cup of tea!

It then only took 20 mins. I jacked the body up which gave a lot more clearance around the axle, enough to get my hand in around the starter to weedle the top bolt into place. It also exposed a clear path to the bottom bolt to tighten it with an impact wrench.

Half an hour later, I had the twin-transfer all bolted up to the Vitara auto box. Now the serious fabrication can begin! The bloody starter motor has put me nearly a day behind schedule.

The next step is to make the gear and transfer box mounts. At the moment it's all held in with ratchet straps. Once I know the final positions of the flanges on the SJ410 transfer box (part of the twin transfer setup), I'll have some idea where the prop shafts will need to run and can fabricate the frame which will carry the joints for the front & rear single link A frames.

The frame is going to bolt to the original trailing arm mounts. God knows how I'll support the chassis once the axles etc are removed - but some botch solution will occur know doubt!

I'll post some photos in the week.

Si

Hopefully, this will have uploaded a couple of photos of today's work - the double transfer held in mostly with ratchet straps!