Howski's Defender 90 Build Thread

Howski

Well-known member
stolenheron, sorry I forgot to mention it. I may be heading out there next Sunday for a shakedown run before SAE. let me know if you'd be interested

winn, I travel to Americus pretty regularly for work. when the weather cools off I'll bring the 90 down and we should meet up for lunch

i'll just be getting to fix the fuel leak today so unfortunately no wheels/tires on yet. hopefully I will have those on sometime early this week and get to have a shakedown run next Sunday. really looking forward to SAE this year
 

Howski

Well-known member
Tires and Wheels

I put in quite a bit of labor on Labor Day to get the fuel leak fixed. I replaced all the old rusty hardware which made it much easier to get the tank back into place than it was to drop down. Moral of the story, be careful when using tools that cut.

Here's a look at the new wheels and tires. Wheels are factory alloys. Tires are 285/75/16 Maxxis Bighorns I purchased used locally. Not my preferred tire but they have good tread, are in great shape and the price was right. Unfortunately, the lugs that were on my old alloys will not work with these wheels. I can't exactly put it into words how but I wouldn't consider it safe to drive so it will sit for a couple of days. It's a drastic improvement cosmetically and obviously will be off highway as well.

This is probably the extent of any off-road oriented mods I'll be doing for now. The next few things I'll be addressing are cleaning up the interior, fixing some small water leaks in the roof and installing a few tie-down points for securing gear in the rear. If the new lugs arrive in time I may try to do some light riding this upcoming weekend before SAE. If not, I look forward to seeing some of you at SAE and will have plenty of pictures up afterwords.
 

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Howski

Well-known member
Had a pretty good time at SAE this weekend. After getting off to a bit of a late start, I got stuck in Atlanta rush-hour traffic and subsequently missed the Friday night ride. I just got set up friday night and hung out at camp. On Saturday I ran Beasley Knob with a group of about 8 trucks. The Defender performed great on the trails. It's obviously very different on the trails than my D2 which was locked front/rear. For the moderate trails at Beasley it was more fun and challenging with open diffs and a stick shift. That being said, lockers will likely be in my future down the road. I won some shirts/hats and free registration to next year's event during the raffle that evening. I also picked up some RTE Engineering gift cards at a great price during the auction. I plan to put them towards some 2" lift springs later this year. I managed to get packed up and back on the road pretty early Sunday morning.

After performing flawlessly all weekend, I ran into a troublesome issue on the way home. After coming out of the mountains, I noticed my clutch pedal needed to be depressed a little further and thought nothing of it, figuring that it probably got a little warm shifting frequently up and down the hills. After a stop for a few hours, I continued and the clutch still felt the same. After several miles on the highway, I noticed that I had almost no clutch pedal at all and was low on diesel. I managed to exit and fuel up, however the clutch would now only engage about 1" from the floor. I topped off the clutch (which was nearly full) and managed to get it back on the highway and home. I've read several threads on clutch issues (on other forums) but my symptoms don't really seem to fit most of those as there were no leaks (master cyl. was nearly full of fluid) and there is no slippage after the clutch is engaged. Any input from those with LT77 clutch experience would be great.

As usual, I failed to take many pictures this weekend. The pictures I do have (mainly of other people's trucks) I'll post up later on.
 

LR Max

Local Oaf
Have you tried pumping the clutch pedal? After pumping did you get a firm pedal (at least for a little while?) If so then it is most likely your master cylinder.
 

Howski

Well-known member
Have you tried pumping the clutch pedal? After pumping did you get a firm pedal (at least for a little while?) If so then it is most likely your master cylinder.

I tried that and it didn't really do much. Gave me slightly more pedal but nothing notable
 

Howski

Well-known member
A nice juicy air bubble having a little party inside the line somewhere?

I plan to try and bleed it this afternoon but I'm a little concerned as to how the bubble would have gotten there in the first place.
 

LtFuzz

Explorer
I plan to try and bleed it this afternoon but I'm a little concerned as to how the bubble would have gotten there in the first place.

I haven't had many air bubble issues on my trucks, but on motorcycles they're very common -- the older, basic systems just aren't as closed as one would like. Even when the reservoir is full, a little bit of sloshing around can allow just enough air into the line to create an issue. I expect if you bleed it you'll be good to go. Do you have a vacuum bleeder?
 

Howski

Well-known member
I tried using a vacuum bleeder last week with no success. Had a friend stop by yesterday to help me bleed it out and it's back to normal. Hopefully I won't have any more issues but I've learned quite a bit on the subject reseraching my problem. I purchased wheel center caps and a black plastic style grille to enhance the asthetics a little bit. It's amazing what some little changes can do to give the truck a facelift. Also, I finally got it registered today too
 

Howski

Well-known member
Made a 400+ mile trip this past weekend without a hitch mechanically. It rained pretty hard the entire way back and needless to say, I have some weather proofing to do. There is a slight leak somewhere in the roof and along the passenger door threshold. These weren't major and didn't leak unless the truck had been sitting, allowing some water to collect on the roof. The biggest pain in the rear was water that kept getting on my feet. I haven't had a chance to track it down yet but it was pretty miserable having my foot constantly soaked for nearly 4 hours. I have a few free weekends coming up so a timing belt change and tracking down and fixing all the water leaks will be on my short list.
 

Jitterbug

Adventurer
I havent had a defender yet that doesnt drip on your feet when the road is very wet. Think of it as a hydrotheroputic foot spa, it would cost $$$$ as an option on a BMW!
 

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