Renew my bios plate

**frostythor** · 27th July 2020, 02:46 AM

After having the car for 14 years I decided it was time to replace the Bios plate to get rid of the wobbly gear lever, I check out you tube found a go video, .... a got stuck in, drilled out the 9 pop rivets

I found my inner seal torn , and tried every where to get a replacement for a now not in production piece of rubber, no luck, but how to fix it,

I did try gluing with a gasket seal it seamed to work OK but wanting to reinforce it more I was stuck as I could not get a decent section of rubber to use,....

a flash of inspiration I went to my local tyre store, asked for and got on old inner tube

enough good quality rubber to do both sides of the torn Gaiter

on the video the man doing it found it hard to replace the 2 springs so I did it a different way

I did the right one first, I screwed the spring bolt in approx half way the put the gear box in first the spring was easy to lift up and past the gear lever with a long screwdriver, then ran the bolt almost fully in

left spring the same only this time I put the box in 5th gear and did the same

now having drilled the pop rivets out I decided that I would replace the with self tapping bolts and screw plates a lot easier to get off again if I need too

and you can see one side of the repaired gaiter were I used the inner tube.

,

**4runnernomore** · 27th July 2020, 11:50 AM

Good luck with the inner tube repair. I hope it holds for you

Been down this road Before and admittedly my Cover was in worse condition the repair did not hold. I put it down to the cover was in bad condition (rubber was already perishing) the wrong glue, (triedsikka), the extreme heat in the Territory ( gearbox oil temps would go up to 90 during the buildup with outside temps hitting 50 travelling on the highway) and the fact the cover was under constant strain ( 50 mm body lift).

I was lucky enough to source a mint Second hand replacement out of England in very good condition Thanks to a eBay notification in my thread. I enquired with a number of business’s In Australia about having the part AWR5526 remanufactured however the same result all round. Not financially viable.

I sincerely thank Nugget for all his enquires and effort that he went to as well as advice from Mario whilst I was researching this.

My mechanic Leigh (formally Nightcliff Service Centre now LR Automtive NT) did a fantastic job on my metal gearbox tunnel cover By modifying and dropping the gaitor position down 50 mm to where It should be from factory Releasing the pressure on the rubber gaitor which will hopefully keep the cover from splitting in the future unless a ham fisted mechanic doesn’t take enough care if the gearbox ever has to come out again( which Hopefully it won’t need to with a new rebuilt HD Ashcroft modified gearbox and transfer fitted 2018 and then some significant engine repairs in 2019 including new clutch replacement).

It is hard to believe that none of the aftermarket industry took up the manufacture of this part as there must be thousands of manual D2’s around the world with the same issue.

I am just happy mine is no longer damaged or torn and finally seals out some the heat, road noise and hopefully dust and water entering from the transmission tunnel and into the cabin.

cheers, Chris

**frostythor** · 27th July 2020, 06:01 PM

Hi I edged my bet, the gaiter has inner tube on both sides, one side super glue the other gasket rubber seal, I have a plan 'B', Im fabricating a metal plate in the same shape as the gaiter, to take a smaller gear cover,

**PhilipA** · 27th July 2020, 08:41 PM

I might be biased but I think BIOS stands for Basic Input/Output System.

Regards PhilipA

**d2dave** · 3rd August 2020, 10:41 PM

Originally Posted by 4runnernomore

It is hard to believe that none of the aftermarket industry took up the manufacture of this part as there must be thousands of manual D2’s around the world with the same issue.

I would have thought that the bulk of D2's were autos. It appears that way in Australia.
Not sure about overseas though.