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dhallworth

Member Since: 10 Oct 2011
Location: Glasgow
Posts: 3072

2012 Range Rover Autobiography TDV8 Baltic Blue

Front end now reassembled. I noticed on reassembly that although the brake discs are well above the minimum thickness the brake pads were knackered so on Saturday evening I ordered some EBC Greenstuff 6000 pads for it.

Thankfully, EBC dispatched my brakes very quickly… they should be delivered by UPS tomorrow.

Just ordered all of the bits for the rear suspension rebuild tonight. 😳 Compared to the front, the parts for the rear are expensive! Small bushes that would fit in the palm of your hand are £50 each! I’ve only bought Genuine LR parts wherever possible and bought from eBay and Island 4x4 and my parts bill is a tad over £550!

To change the upper wishbone bushes at the rear you need to drop the rear subframe to access the nuts. As I’ve bought the big subframe bushes and am going to do them at the same time, I think I’m going to drop the entire subframe and do everything on the bench before offering it back up to the car, it’ll give me a good chance get in about it with a wire brush, some Bilt Hamber Hydrate 80 and some paint whilst it’s off the car.

Gotta have something to do with the diff being away for rebuilding!

I must be mad!

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

7th Mar 2022 10:49pm

Jayk69

Member Since: 08 Feb 2018
Location: Daventry
Posts: 601

2012 Range Rover Vogue 4.4 V8 Barolo Black

hell Dave you like to work looking forward to the rear stripdown. 2012 Vogue 4.4 TDV8 - Current
2014 Navara V6 - Gone
2004 Vogue TD6 - Gone
Grand Cherokee - Gone
Discovery V8 (LPG) - Gone
Discovery TD5 - Gone

8th Mar 2022 7:56am

dhallworth

Member Since: 10 Oct 2011
Location: Glasgow
Posts: 3072

It seemed ike a good idea at the time

The rear diff has a whine from it as the bearings are noisy which is my reason for doing the rear, occasionally I heard a rumble from the front when on overrun so at least it's gonna be sorted now.

Didn't see much point in putting old rubber or ball joints back on when it had all been in bits either as it's a 15 year old car...

My wallet wishes I hadn't of made that decision though!

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

8th Mar 2022 10:27am

maric995

Member Since: 04 Apr 2019
Location: zagreb
Posts: 58

2006 Range Rover HSE 4.4 V8 Zambezi Silver

Hi David,

Nice work
Can you post a few photos of the rear diff bolt mount location when you will be removing it?
This job is also on my list, so I will appreciate it

You become a banker or engineer with this cars RR HSE 4.4 2006 LPG

9th Mar 2022 7:32am

dhallworth

Member Since: 10 Oct 2011
Location: Glasgow
Posts: 3072

Will do

They're easy enough to see when looking around the diff but am not sure how easy they are to get to!

I'm changing the mounting bushes for mine whilst it's out too.

If it's any help, the part numbers are:

2 x KHC000030 (front of diff to subframe)
1 x KHC000040 (rear of diff to subframe)

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

9th Mar 2022 1:14pm

dhallworth

Member Since: 10 Oct 2011
Location: Glasgow
Posts: 3072

Well, UPS have managed to loose the EBC brake pads I ordered so no sign of them arriving as of yet.

I've finished painting the calipers and have applied the transfer to the NS one. Am really pleased with how it looks now.

I then took the cover off the back plate and saw the state of that and wished I'd had time to treat it whilst I had the bearings split. I'm not happy with the look of the backplate so that's been wire brushed and treated now too.

I'm really

off with myself though as I didn't check the pistons in the calipers were free before cleaning and painting them. When pressing them back last night one of the pistons in the NSF caliper is jammed so I've ordered a caliper rebuild kit which should be here tomorrow. I'm hoping I can get them rebuilt without having to split the calipers in half.

One of these days I might be able to get it finished and driving again!

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

9th Mar 2022 1:25pm

dhallworth

Member Since: 10 Oct 2011
Location: Glasgow
Posts: 3072

Caliper rebuild kit arrived today.

Dust shields on the new pistons.

I didn’t get any during the rebuild photographs as I had brake fluid on my hands and didn’t want to touch my phone. However, to summarise…

Dipped the square section o-rings in fresh brake fluid to give them a coating.

Fitted the orings into the bores of the calipers.

Put a bit of the provided assembly grease onto the pistons.

Lined the pistons up nice and square in front of the bores and squeezed and with a nice firm feeling the pistons slid nice and easily into the caliper.

I then ensured the dust seals were seated properly and repeated for the other 7 pistons!

As the paint had suffered slightly with the brake fluid and the transfer wasn’t sitting perfectly straight I peeled it off and gave both calipers another coat of paint. Note to self… don’t leave a screw driver on the bench when you’re spraying paint! 🙈

Pins and plates were given a light rub down and given a light coating of copper slip. Pads have been refitted too so once the paint has dried again I’ll get them back on the car. There are 4 new bleed nipples in the box which I’ll fit tomorrow evening when they’re back on the car.

There’s another set of transfers on their way here that should be delivered tomorrow so with a bit of luck tomorrow evening might be the final stretch for the front end!

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

10th Mar 2022 8:03pm

dhallworth

Member Since: 10 Oct 2011
Location: Glasgow
Posts: 3072

Well, the front is now buttoned up and finished off

So summarise, it’s had a new differential, a new support bearing for the longer halfshaft, 2 new wheel bearings, 2 new bottom ball joints, 2 new lower control arms as the ball joint is integral, 2 refurbished upper control arms, 2 new track rod ends, 2 new drop links, 2 new ABS sensors as they were stuck in the hubs, new brake pads, and the brake calipers rebuilt.

Refurbished control arm. New bush pressed in, arm wire brushed, treated with hydrate 80 and then 2 coats of paint.

New control arms with integral ball joints.

New track rod ends.

New Drop Links. I opted for the Meyle HD ones from Advanced Factors with a 4 year warranty. Just need to find the clips I’ve got to hold the ABS sensor cable to the strut now. They’re in the workshop somewhere. 🙄

Click image to enlarge

Calipers finished.

And then the refurbished, ceramic coated wheels were put back on.

Click image to enlarge

The control arms on these are torqued to 165Nm + 90 degrees and need to be done with the car sitting at it’s normal height. I put the wheels back on, started the car, put the suspension to it’s highest setting, dropped it to it’s lowest setting and then set it to it’s standard ride height.

Using diagnostics I then put the suspension ECU into Tight Tolerance mode which means the ECU adjusts the suspension to much tighter parameters then it does normally. I then torqued all the bushes down to the correct setting.

It didn’t last long with the wheels on it though as I wanted to be ready to drop the rear subframe off it tomorrow.

I didn’t make a start tonight as the first step is to remove the exhaust which was roasting hot due to it being running to set the heights.

So, tomorrow morning the work on the back end begins! I was a bit nervous about putting the axle stands on the rear jacking points as some people with these cars have seen the jacking points disappear into the cills when jacking them. Thankfully, mine are sold and there were no crispy noises when putting load on them 😁

First job for the morning is a bit of tidying up as the exhaust is one piece from front to back and takes up a lot of room.

Aiming to have the rear subframe removed and on the work bench by the end of tomorrow.

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

12th Mar 2022 12:28am

Cam-Tech-Craig

Member Since: 03 Aug 2011
Location: Gloucestershire
Posts: 16284

2015 Range Rover SVAutobiography SDV8 Loire Blue

You’ll have a new car sooner or later David… there can’t be much more you can change? Great work though never the less 👍

12th Mar 2022 8:26am

dhallworth

Member Since: 10 Oct 2011
Location: Glasgow
Posts: 3072

That’s kinda my plan, Craig.

Do it once, do it right and enjoy it. I can’t be bothered doing little jobs all the time so it’s quite nice knowing it’s sorted when you drive it out of the workshop.

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

12th Mar 2022 10:12am

Cam-Tech-Craig

Member Since: 03 Aug 2011
Location: Gloucestershire
Posts: 16284

Ahem… But it’s a Range Rover David…

12th Mar 2022 12:49pm

dhallworth

Member Since: 10 Oct 2011
Location: Glasgow
Posts: 3072

Very true Craig

Today went very smoothly

Removed the rear arch liners, removed rear brake calipers (Just as well as found a seized slider), removed the shock absorbers, removed the brake pipes from the rear subframe, removed the air lines for the rear bags, removed the abs sensor wiring from the body, loosened the 4 subframe bolts and started to lower the subframe.

At this point I found someone had run in a new handbrake cable and had it over the steel brake pipe clipped to the body so had to remove the brake pipe as I hadn’t stripped the brakes. I then found the petrol return for the LPG was routed under the handbrake module so had to remove this and re-route it too.

Dropped it a bit further and then found the emergency brake release cable for the electric handbrake was clipped into that wheel arch so I had to climb into the car on the ramp to release that from the boot as the car was on the ramp and the subframe was supported on the transmission jack.

After a bit more fettling the subframe was completely removed. I put a couple of ratchet straps around the wishbones to keep them compressed as it was tight for clearance to get the frame out between the body of the car and the ramp.

I then proceeded on with stripping the subframe.

Every single nut and bolt on the car has come apart perfectly with the exception of 1 piece. The Toe Control Arm on the OS is seized. So that I could remove the hub tonight I cut that off with the grinder and will deal with it tomorrow.

From the underside of the car the subframe bushes don’t look bad… From the top it’s a different story!

Upper wishbone bushes.

Lower wishbone bushes.

Needless to say, they are all due for changing judging by the looks of them! I’d say it’s fairly conclusive that they’re the original bushes at 15 years old!

Tomorrow I’m going to get the subframe unbolted from the diff and get that strapped to a pallet so it can be sent away for rebuilding this week. Monday I’m going to take the subframe in for blasting and I think I’ve decided on powder coating as it’ll save me time.

Then when I’m off work W/C 21st March I’m aiming to have the whole thing back together and out of the workshop.

In between now and then I’m going to get under it with a wire brush and clean up the bodywork as it’s got a chunk of surface rust on it. At least I’ve caught it before it becomes a hole.

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

12th Mar 2022 10:47pm

dhallworth

Member Since: 10 Oct 2011
Location: Glasgow
Posts: 3072

Today saw the remaining few bits being stripped off the subframe including the diff.

I forgot I hadn’t drained the oil from the diff when I removed it so I got the mini digger and picked the whole subframe assembly up so I could reach underneath it.

After that was done, I sat it on top of the toolbox and removed the bolts holding the differential to the subframe and lifted the subframe up again leaving the differential behind.

The company doing the rebuild didn’t want the locking motor so that was removed from the diff and it was all put on a pallet ready to go. They’re also rebuilding a P38 steering box for us and are taking a transfer box I have with knackered bearings as a spare unit they can remanufacture too.

I then stripped the remaining 2 hub assemblies down in preparation for doing the bearings. There was a lump of hard stuff on the CV gator that came off when picked at and revealed a hole in the CV gator. Some sod has done a bodge rather then a proper repair 😡

Anyway, hopefully the pallet will be collected tomorrow or Tuesday and I can crack on with the small jobs whilst the diff is away.

Subframe and wishbones are going for blasting and powder coating this week too.

David. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

13th Mar 2022 8:43pm

Danwilderspin

Member Since: 15 Jun 2016
Location: Cambridgeshire
Posts: 2215

2007 Range Rover Vogue SE 4.2 SC V8 Zermatt Silver

Looking busy! Did you refurb the wheels yourself? Current stable:
2006 BMW M6
2007 4.2 V8 S/C FF
Gone:
2002 4.4 V8 FF

13th Mar 2022 11:36pm

dhallworth

Member Since: 10 Oct 2011
Location: Glasgow
Posts: 3072

I’m afraid not.

The wheel refurb is the only thing that I’ve not done myself. I took them to a local place who acid dipped them, blasted them, powder coated them and baked them.

I took an original, unrefurbished wheel with me for them to match and they did a great job of replicating the original Land Rover Sparkle Silver finish. 2002 4.6 Vogue SE - Alveston Red with Lightstone Leather
2007 Range Rover Supercharged in Java Black with Ivory Leather
2012 Range Rover 5.0 SC Autobiography in Indus Silver with Jet/Ivory Interior
2012 Range Rover 4.4 TDV8 Autobiography in Baltic Blue with Sand Interior

13th Mar 2022 11:40pm

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