Pinzgauer TD

Ok I should have done this ages ago.

Easiest way to get the diff out is a trolley jack (fitted with a larger flat plate), timber and 2 ratchet straps

Both the front and rear diff are the same.  Rear one is slightly easier to remove but the front one has a speedo gear loctited on.  You need a puller and some heat to remove it (0k I didn't have a hot air gun at the time!)

Use a version of a pulling off tool to get the axle tubes off and there is an on ring on the tube.  Our M&H pulling off tool works well, but I want to pretty it up later.

Take the input bearing housing off.  Take the upper casing off

Take the end plates off the diff noting which way is up and which end they are on.  Tilt the axles housings down and pull out the pinion shaft (noting which end goes where and keeping all the shims in place)

Lift out the axle housings, noting where they came from and what is up or down.  On the axle housing these is a wiper seal, rubber stop ring (should be ok - I never seen one broken yet) and a plastic ball cup.  The ball cup on P90 and earlier has an O ring and on P93 uses a sealing paste (the P93 cups are better). 

You need to clean up the mating surfaces

Glue the cup on

Then refit everything in the reverse order.

Take care when reinserting into the central tube.  the short retaining bolts MUST be able to be inserted with fingers, do not force them.  I found the easiest way is to have the pinzgaur jack and you jack up the low point etc until holes line up.  On the front the front bar is attached to a torsion bar.  Bolt those 4 bolts first then line up the casing bolts

If you dont have an ignition key you can take the barrel to a locksmith and get a key made.

Often you have an ignition key but it don't fit the doors.  New handles cost around 10 GBP but you still have to change the lock.

Pull the lock barrel out and note how the spring fits.

Put the key in you want to use then by trial and elimination swap the small key plates around until you get the lock external barrel as flat as possible.  I bit of a puzzle game  don't lose any of the key plate springs

One close you can use a needle file to file down any key plates that still protrude

Finished

Been mounting the aircon on the roof and decided to service a few items.  I noticed the fans were not moving by hand which I thought was odd.

I opened the fans and found this inside

Update 7th March 2011

Well seems to be the fuel Injection pumps in P80 (NA), P90 (TD) and P93 (TID) are all different.  Not quite sure on the injectors at this point but the output pressure and RPM parameters are higher.

Also the P93 one is Pinz specific.

P93 Type number is : 0 460 406 078

Update 4th November 2010

075 130 107 B: Injectionpump complete for Pinzgauer TD (P80 / P909 with engine code no.: NY …..

758 1 08 020 0 : Injectionpump complete plus fastening plate for Pinzgauer TD (P80 / P90 ) with engine code no.: NY ….

(7581080200 consists of: 075130107B Injectionpump + 7581080012 Fastening Plate)

075 130 107 T: Injectionpump complete for Pinzgauer TD with air intercooler (P93) with engine code no.: ADB ……

these are fairly common merc part but the number may be useful

New fuel filter

Hot from Ebay

Mines not leaking but taking the box out may as well change it

The new one has does not appear to require a gasket as has a ridge built in

Fitted to Benz W123

Definately not a job for the faint hearted.  Easiest way is have a spare wrecked P93 to get the parts from.  Can be done by other means but a bit of fabrication is required e.g.:

- Need the P93 intercooler lower mounts welded beside the bumper mounts

- Upper radiator / intercooler mounts are different

- Leading edge of radiator tunnel needs to be trimmed back

- LHS and RHS floors have recessed area so the intercooler tubes fit beside the front frame

- Front frame is different

- Front nose is different (has additional space for top radiator mounts and lower nose mounts are different

- Need lower nose mounts

- different frame spacers

- intercooler piping (Note: one pipe not in picture)

- turbo is different in respect to settings and orientation (not sure on the p/n as yet as my P90 one is still in)  UPDATE (01/10/10):  P93 turbo definately different!!!!!!  P90 is VW 075149703 (GAP 466088-1) and P93 is VW 072145703B (GAP 454007-1)

- Aluminium inlet housing is different

- Injection pump settings are different

- turbo upper oil ine hose and fittings different

Off the ZF site I found the part number is :

Fichtel & Sachs AG: MF 240

Sachs (ZF SRE) 883082

The ones I took out today are Sachs (ZF SRE) 201862106102 & 063082161.001