D2 Bottle Jack Replacement

[Rymnd]

G'day all.

Any suggestions for a good bottle jack replacement that will fit in snuggly behind the ECU?

Thanks!
Ray

[Tombie]

Rebuild it. There’s a full write up on here.

They’re a great jack

[gavinwibrow]

Rebuild it. There’s a full write up on here.

They’re a great jack

If you can't find it, I have it in my files somewhere and can email the pdf to you. If I recall, its to big to PM and will need a private email address.

[AK83]

https://www.aulro.com/afvb/local_links.php?action=jump&catid=2&id=129

[Pedro_The_Swift]

Typical land rover,, they design a great jack, then lay it on its side.... :bat:

[Bohica]

The jack needs to lie down and rest, after lifting such a magnificent vehicle.

[reefmagnet]

You can tell it's a designed for Land Rover jack by the way it leaves it's own oil puddles on the driveway.

[PhilipA]

Have you just refilled it with oil and tried it?
Mine gave up in Kempsey when I got a flat. Went to Supercheap for some oil filled it up and bob's your uncle.
Regards PhilipA

[reefmagnet]

This thread got me pulling apart my jack today. The big seal between the bottle and the base has given up the ghost. Is a seal kit still available for these things?

[Rymnd]

Thanks all for the responses. Tried filling up with new oil but still gushing out when under pressure.
I started following the instructions but am at a point and unsure how to continue.
Undid the sealing screw, but nothing's coming undone any further. See pic.
What should I unscrew next to get the piston out?
173179

[PhilipA]

Just be careful if you separate the top piston from the bottom one, as the seal is not an oring but some multi piece device.

My original jack had a bent top piston, so I bought another one from a wrecker in Victoria .

I then tried to fix the original one by reaming out the bottom piston to allow for the bend.

I replaced the seal with an oring and it does work , but I do not trust it .
I now store it in a plastic zip bag that will tell me how much oil is leaking. It is usually not much but builds up over the years. It usually leaks out of the bottom where the outside attaches to the base, as it is sealed by an oring.
Regards PhilipA

[Tombie]

Just be careful if you separate the top piston from the bottom one, as the seal is not an oring but some multi piece device.

My original jack had a bent top piston, so I bought another one from a wrecker in Victoria .

I then tried to fix the original one by reaming out the bottom piston to allow for the bend.

I replaced the seal with an oring and it does work , but I do not trust it .
I now store it in a plastic zip bag that will tell me how much oil is leaking. It is usually not much but builds up over the years. It usually leaks out of the bottom where the outside attaches to the base, as it is sealed by an oring.
Regards PhilipA

You replaced a SIngle Acting U packing with an Oring?

Ffs. I wouldn’t trust it at all now.

[Rymnd]

Just seeing if anyone can shed some light on my situation...


Thanks all for the responses. Tried filling up with new oil but still gushing out when under pressure.
I started following the instructions but am at a point and unsure how to continue.
Undid the sealing screw, but nothing's coming undone any further. See pic.
What should I unscrew next to get the piston out?
173179

[Rymnd]

This thread got me pulling apart my jack today. The big seal between the bottle and the base has given up the ghost. Is a seal kit still available for these things?
I’ll probably need to be looking for a seal kit too. How did you get the top undone/unscrewed to pull the pistons out?

[reefmagnet]

I’ll probably need to be looking for a seal kit too. How did you get the top undone/unscrewed to pull the pistons out?

I haven't pulled the pistons out as there's no need for the reservoir and I tested the jack's pressure side and it was fine. However, I have a document I downloaded from here that describes the procedure as


Withdraw the piston from the cylinder - use a seal pick to remove the seals. The damaged
seal just below the seal screw on the piston in image 2 can be replaced with a square seal or
an O- ring with a nylon/Teflon backer. Alternatively clean up the damage done to the
sealing ring on removal. If you install a backer and O-ring combo it must be installed with
the backer nearest the seal screw.

I used a pipe wrench to undo the collar and then gave the bottle part a couple of taps with a leather mallet to jar it loose. It is, surprisingly, made of plastic so don't wack it too hard!

[Rymnd]

I used a pipe wrench to undo the collar and then gave the bottle part a couple of taps with a leather mallet to jar it loose. It is, surprisingly, made of plastic so don't wack it too hard!

Thanks for the info. Plastic! How about that! The sealing screw came off relatively easy but the thread part underneath (that the screw came off from) is the one I’m stuck at. How does that one come out?

[PhilipA]

surprisingly, made of plastic so don't wack it too hard!

Some are plastic some are steel.

BTW I only use my repaired jack to do things like jack the axle down to change springs, not in any load .

My assumption was and is that I cannot get parts for a 20 year old Italian Jack. LOL.
Regards PhilipA

[Tombie]

Well your assumption is incorrect [emoji41]

[Slunnie]

Can you get rebuild seal kits for them?

[Tombie]

Can you get rebuild seal kits for them?

Not as a kit, however a good hydraulic seal mob should be able to supply.

I made up a few kits when I had the hydraulic company in Adelaide 20 years ago, and it was easy to obtain parts.

[Rymnd]

So I had some success in getting the thing apart without breaking anything. I stumbled across a clip online to use olive oil to rejuvenate o-rings and it worked for the outer piston o-ring.

I put the whole thing back together, and now the inner small cylinder's leaking in the middle.

So, how does one take that bit apart! :-) The link with the instruction don't seem to cover that bit...

[Rymnd]

I managed to get the whole thing apart and thought I'd share my experiences. Here's my process:

1) Take filler hole plug out and drain oil. Used small screwdriver, wiggled in at side of plug, push all the way through and pivot bung out.
2) Undo the sealing screw. Used a punch and tapped gently. Then screwed off by hand.
3) Remove top v-part from inner cylinder. Placed jack in loose vice and used punch to tap in middle. That part then comes off easily.
4) Removed the main "bottle" part (plastic) with a filter removal pliers. Slide the whole thing off.
5) Placed piece of bicycle tubing over the main metal cylinder and used waterpump pliers to loosen and turn out. Any damage can be easily smoothed by using needle files.
6) Remove the inner cylinder from the outer by tapping with a punch. It comes out easily at the bottom.
7) Check seals and clean.

In my situation, the top o-ring of the inner cylinder was broken. Bought a bog of o-rings at Supercheap, but none worked. Found a set on RS that appears to have the same measurements.
"RS PRO Nitrile Rubber O-Ring, 19mm Bore, 21.6mm Outer Diameter". I haven't ordered it yet, but the measurements are similar to what I took when the thing was open.

Also, the outer cylinder's o-ring could use a replacement. I'll do the measurements next time it's open. (Unless someone has that handy, as I put mine together again pending the arrival of the o-rings...)

Hope this helps.

Cheers.
Ray

173267173268

[Tombie]

So I had some success in getting the thing apart without breaking anything. I stumbled across a clip online to use olive oil to rejuvenate o-rings and it worked for the outer piston o-ring.

I put the whole thing back together, and now the inner small cylinder's leaking in the middle.

So, how does one take that bit apart! :-) The link with the instruction don't seem to cover that bit...

You cannot rejuvenate an oring.
What you have done is make it swell which then weakens it.

[marshn]

I am going throught the same excercise to try to stop my jack emptying its oil into the compartment by the battery.

The seal in the picture that Rymnd (https://www.aulro.com/afvb/members/82652.html) posted is in a bad way. It should be what I think is called a 'slider seal' that sits on top a an o-ring (in the same groove) acting as an 'energiser'.

These are photos of the seal and the o-ring from my jack, which might help identify a replacement seal. The dimensions of the seal (as best as I can measure it) are ID=0.735", OD=0.885" Width=0.123"

173288 173287

I have measured most of the o-rings, and they seem to be BS1806 series, rather than metric sizes which I would have expected in an Italian jack. I have ordered some replacements and once they arrive, if I can confirm that they are the correct size, I will post a list of their sizes and positions.

Regards, Neil

[Tombie]

Neil. Please measure the groove ID, groove width and the bore diameter that the seal goes into.

[laney]

I just brought a 10 ton bottle jack fits where the old one was lifts like a charm.

[Rymnd]

What’s the make? Where did you buy? I got one last week from Autobarn that was supposed to fit, measurement wise, but didn’t.


I just brought a 10 ton bottle jack fits where the old one was lifts like a charm.

[marshn]

Thanks Tombie,

The measurements for the groove at the bottom of the inner piston (that the o-ring and 'slider' seal fit into) are:




Bore ID
Width
Bore


14.50
3.25
22.00 mm


0.571
0.131
0.866 inch




I take back what I said about these seals not being metric. This has got to be a metric seal?
Any leads for a replacement slider seal welcome.

For reference, the grooves for the plain o-rings which seal the two pistons are:




Desc
Bore ID
Groove Width
Bore


Inner piston, wiper o-ring at top, installed into groove in top of outer piston.
Groove depth (1.54) measured (and bore calulated)
19.00
2.75
22.08


Outer piston, main seal at bottom.
Sits above a wear ring in same groove which is 1.30 wide, total groove width is 5.10
27.40
3.80
32.00


Outer piston, wiper o-ring at top, installed inside groove in top of cylinder.
Groove depth (1.82) measured and bore calulated
28.30
3.50
31.96



Any suggestions for the o-ring sizes would be welcome. I will see if a 19x2 fits the first one, and 27x2.5 for the other two in this table.

[Defender08]

My bottle jack leaked out of the top piston seal and in the instructions on repairing the bottle jack it stated:
"If the jack creeps down and/or forces fluid out of the top of the bottom lift piston, then the top piston seal is faulty and the jack is typically not easy to repair at the handyman level so is not covered in this instruction."
So I stored my jack and went back to an old Lightburn 2 stage lift jack with much reduced lift range and glued a block of wood on the base.
I've been watching this discussion to see if I can get information to repair the top piston seal and return to using my original bottle jack. Can contributors suggest what might need to be added to these instructions so that the top piston seal can also be repaired?

[vbrab]

My bottle jack leaked out of the top piston seal and in the instructions on repairing the bottle jack it stated:
"If the jack creeps down and/or forces fluid out of the top of the bottom lift piston, then the top piston seal is faulty and the jack is typically not easy to repair at the handyman level so is not covered in this instruction."
So I stored my jack and went back to an old Lightburn 2 stage lift jack with much reduced lift range and glued a block of wood on the base.
I've been watching this discussion to see if I can get information to repair the top piston seal and return to using my original bottle jack. Can contributors suggest what might need to be added to these instructions so that the top piston seal can also be repaired?


Because hydraulic bottle jacks usually (often) end up leaking (and I don't trust hydraulics not to fail when you least expect it), I have always replaced them with a Landcruiser/Prado type wind up bottle jack.
Not a lot harder to get into place (being slightly taller than the D2 bottle jack), but they cannot fail and are fairly cheap, and readily available second hand.

[vbrab]

G'day all.

Any suggestions for a good bottle jack replacement that will fit in snuggly behind the ECU?

Thanks!
Ray

I always replace the hydraulic jack witha wind up Toyota type jack from either a Land Cruiser or prado, with one being slightly shorter than the other.

[DazzaTD5]

*ALL jacks have the potential to fail, dont get under a vehicle just on a jack or you will end up in the news... "idiot dies after jack fails and huge bus crushes him"

*Yes the D2 jacks really are the best, I have one in the Perentie, Defender TD5 and the Defender 200tdi. I have also given a few to long term customers over the years before I realised their value [tonguewink][tonguewink]

[Tombie]

I always replace the hydraulic jack witha wind up Toyota type jack from either a Land Cruiser or prado, with one being slightly shorter than the other.

Had a few wind up mechanical units fail.
Right when we needed them.

Never trust any jack!

[AK83]

Had a few wind up mechanical units fail.
....

The old Rover P6 jack was my favorite jack type I've had to use.
Dad's Cadillacs also had very easy to use jack too.

Both were mechanical high lift types(but not high lift).
The Caddy jack had a hook system to attach to the bumpers, and an easy to use lowering mechanism. Didn't fail(only used twice that I recall)

My P6 jacks more regularly and I never had the depressing deflation of having a flat tyre in the P6's. Another highlift type but with a bevel gear in the head and a crank handle.
Awesome thing to use and not overly large.
But one time I placed it (what I thought was an ok spot) but the ground gave in and the jack splayed itself outwards. Extremely hard to wind it now due to the angle of the dangle, but nothing else to do .. and of course the gear stripped itself. Now jammed up a bit too high.

So yes, mechanical jacks can fail.

Being a Jap jack .. it wont be made of rust proofed material, so will rust itself jammed if not used(or looked after).

[RRT]

Doing the back suspension today and got the bottle jack out for its first use (not a mark on it so thinking it was never used before) and would only get to about 4 cm's of travel. Remove the bung and fill and easy. The bung as a case in point was under the jack when I got it out, so if this is the leakage point it now sits high. Where do people store them if they have gone the double battery tray, not sure I want hydraulic oil leaking out in the car...

[biggin]

I store my jack upright in a Milwaukee power tool bag with all my recovery gear, stored in the back of the car. The old jack space is used for my winch controls.

[Slunnie]

Doing the back suspension today and got the bottle jack out for its first use (not a mark on it so thinking it was never used before) and would only get to about 4 cm's of travel. Remove the bung and fill and easy. The bung as a case in point was under the jack when I got it out, so if this is the leakage point it now sits high. Where do people store them if they have gone the double battery tray, not sure I want hydraulic oil leaking out in the car...

Hmmm, maybe I should pull my old one out and give it a refill then see what happens. I have mine in the rear side bin.

[laney]

I brought my 10 ton jack from total tools

[Tombie]

Used mine again today, on the 90.

Perfect to quickly lift it, stands underneath and a set of alignment bushes fitted into the front arms.

[V8Ian]

I got a 15 tonne squat jack for my coach, squat enough to go under the Disco. Under a hundred bucks from Maxiparts, truck stuff purveyors.

[vbrab]

I have always been wary of "scissor" type jacks, from experiences in my youth with those early Holden examples that appeared to collapse on a whim.
Couple of years ago I saw a fellow pull into remote Kumarina roadhouse (WA Pilbara), in a very new Range Rover Vogue with a deflating rear tyre.
So out came the vehicles jack (it appeared to be a sort of scissor/wind up type jack), that worked from the side of the vehicle.
He chocks a wheel, loosens the wheel nuts, and starts to wind.
Initially it started to lift, and then the jack just appeared to collapse (fold), and that was the end of the jack.
No idea what was the problem with the jack, but luckily somebody produced a trolley jack and problem was sorted.
My thought at the time was surely LR could have supplied a more robust jack than one which died on its first outing, and that he was lucky he was at a roadhouse when he noticed the tyre issue.

[Rymnd]

Update on this post. I replaced the seals more than a year ago and there's no leaks. So thought I'd share details of seals I purchased.

22 x 14.5 x 3.2 PU Cap Seal
28.24 x 2.62 O-ring NBR D90
18.77 x 1.78 O-ring NBR D90

The large seal at base wasn't replaced. I'd rate replacing that one would be a good next move, so they get pretty hard over time.

Hope this helps!


I managed to get the whole thing apart and thought I'd share my experiences. Here's my process:

1) Take filler hole plug out and drain oil. Used small screwdriver, wiggled in at side of plug, push all the way through and pivot bung out.
2) Undo the sealing screw. Used a punch and tapped gently. Then screwed off by hand.
3) Remove top v-part from inner cylinder. Placed jack in loose vice and used punch to tap in middle. That part then comes off easily.
4) Removed the main "bottle" part (plastic) with a filter removal pliers. Slide the whole thing off.
5) Placed piece of bicycle tubing over the main metal cylinder and used waterpump pliers to loosen and turn out. Any damage can be easily smoothed by using needle files.
6) Remove the inner cylinder from the outer by tapping with a punch. It comes out easily at the bottom.
7) Check seals and clean.

In my situation, the top o-ring of the inner cylinder was broken. Bought a bog of o-rings at Supercheap, but none worked. Found a set on RS that appears to have the same measurements.
"RS PRO Nitrile Rubber O-Ring, 19mm Bore, 21.6mm Outer Diameter". I haven't ordered it yet, but the measurements are similar to what I took when the thing was open.

Also, the outer cylinder's o-ring could use a replacement. I'll do the measurements next time it's open. (Unless someone has that handy, as I put mine together again pending the arrival of the o-rings...)

Hope this helps.

Cheers.
Ray

173267173268

[Tombie]

Update on this post. I replaced the seals more than a year ago and there's no leaks. So thought I'd share details of seals I purchased.

22 x 14.5 x 3.2 PU Cap Seal
28.24 x 2.62 O-ring NBR D90
18.77 x 1.78 O-ring NBR D90

The large seal at base wasn't replaced. I'd rate replacing that one would be a good next move, so they get pretty hard over time.

Hope this helps!


Piston seal #GP6-022014-032
BS122 (I’d recommend N70 over N90)
BS018 (again N70 over N90)

[Tins]

Pity the old Smith's JackAll system no longer exists....

[Tombie]

Pity the old Smith's JackAll system no longer exists....

181947

Several versions of a modern take on this are out there.
Used for containers onto trucks, race cars etc.

[MAF Diver]

I brought my 10 ton jack from total tools

Does it look the same as this 4 ton one? And it fits in the engine bay?

SIDCHROME 4000kg Hydraulic Bottle Jack SCMT82004 | Total Tools (https://www.totaltools.com.au/203857-sidchrome-4000kg-hydraulic-bottle-jack-scmt82004)