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Old Leafsprung Land Rovers
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#Post#: 1346--------------------------------------------------
How to rebuild a steering relay.
By: Jackual Date: January 7, 2012, 3:53 am
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A commonly neglected part of any Land-rover, The seals wear out,
Leak all the oil and eventually start to sieze.
After seeing one OLLR's members replacement relay shaft shear, I
decided to rebuild the original, After all, How hard can it be!?
A quick word of warning, There is a coil :-\ spring held under
compression,
Treat it with respect and it will be good to you, Twat it about,
And it'll go shitstorm.
Also re-fitting the spring calls for special tools, Although
there is a few different ways of doing this job.
The first thing to do is remove the drag links by the TRE's,
Then loosen and remove the pinch bolts holding the relay upper
and lower levers, Remove the levers, Note the position.
Then at the top of the relay undo the two long through bolts.
Drain the oil (if any) by removing one bottom screw(7/16Early
models 5/16Late), And one top just to let air in.
The relay can now be pushed up out of the chassis, I'll leave
this part up to your imagination, If it won't budge, Don't
panic, It can be rebuilt in place.
Once out it'll look a bit like this;
http://i8.photobucket.com/albums/a1/hey124/RIMG0225.jpg
The one I've got here is out of a scrap chassis, Cut out the
section complete with the relay.
It was rusty, So the scale was removed using a wire wheel in an
angle grinder;
http://i8.photobucket.com/albums/a1/hey124/RIMG0226.jpg
Then onto the strip down, I removed the four bottom screws
holding the retaining plate on, It won't spring to bits just
yet, Just dont hit/drop/ect.
http://i8.photobucket.com/albums/a1/hey124/RIMG0228.jpg
OLLR top tip; Put the relay in an old pillow case when
drifting/clouting out the shaft and the spring.
http://i8.photobucket.com/albums/a1/hey124/RIMG0153.jpg
Retrive all the parts out of the pillow case;
http://i8.photobucket.com/albums/a1/hey124/RIMG0230.jpg
Make note of the parts from the top and bottom, The split tufnol
bushes are a matched pair.
I then remove the screws holding the top cover and remove the
remaining parts;
http://i8.photobucket.com/albums/a1/hey124/RIMG0231.jpg
Parts you should now be able to see;
Two bronze thrust washers,
Two steel washers,
Two end caps with seals,
One spring,
One Relay shaft & Housing.
Clean up the parts, I just use brake cleaner, works a treat on
the tufnol bushes. Check the parts for wear, The bronze thrust
washes and the split tufnol bushes especially.
Don't worry if the surface the split bushes run on the shaft is
pitted, This will aid lubrication by holding the oil, Something
Land-rover later added into the design by cutting a groove in
each split bush.
Also check the surface the seal runs on, The early models will
be a one peice shaft, Later ones have sleeves that can be
replaced if the seals have worn a groove in it.
Painted the body and cleaned up the rest of the parts;
http://i8.photobucket.com/albums/a1/hey124/RIMG0232.jpg
And thats where I left it tonight.
================================================================
==========================================
I did a little work to the relay during the week,
The sleeves the seal runs on look a little worse for wear, so I
decided to replace them, Part no 230184.
http://i8.photobucket.com/albums/a1/hey124/RIMG0235.jpg
To remove them I tried heat and a chisel, That didnt budge them,
So in the end I ground a flat spot and split them, They then
slid off.
I did catch the shaft the odd place with the grinder, But not to
worry.
http://i8.photobucket.com/albums/a1/hey124/RIMG0236.jpg
Just to wait for the bits to arrive and It'll be going back
together.
================================================================
==========================================
Put it together this afternoon with no problems,
The tool I use to refit the spring is a simple pair of clamps;
http://i8.photobucket.com/albums/a1/hey124/RIMG0002-4.jpg
There made from a flat bit of steel, With the ends bent over in
the vice, So the distance between the two is about 60mm, And
then using and angle grinder, I removed some material to make
the tangs that hold the spring.
Then some 2" hose clamps, And a couple of 50mm long 3mm thick
steel bar used as compressing bars.
http://i8.photobucket.com/albums/a1/hey124/RIMG0001-2.jpg
I first compressed the spring in the vise, Using the compressing
bars;
http://i8.photobucket.com/albums/a1/hey124/RIMG0003-4.jpg
Squashing it to a length of 60mm so that the clamps can fit
around it;
http://i8.photobucket.com/albums/a1/hey124/RIMG0004-3.jpg
Then fit the clamps, I use a couple of cable ties to hold them
in place, Then gently ease off the vise, Making sure the clamps
stay in position;
http://i8.photobucket.com/albums/a1/hey124/RIMG0005-3.jpg
Once the tension is placed on the clamps the compressing bars
will fall away, Be carefull handling the spring now!
I worked out doors today, So welcome to my outdoor workbench!,
The main shaft has been cleaned up, And the distance peices
pressed on using the hydraulic press;
http://i8.photobucket.com/albums/a1/hey124/RIMG0006-4.jpg
Start assembling by sliding the compressed spring onto the
shaft, Followed by a steel washer at each end;
http://i8.photobucket.com/albums/a1/hey124/RIMG0007-4.jpg
Then using the Jubilee clips, Place the tufnol bushes on the
shaft held in place with the jubilee clip, Make sure these are
tight!;
http://i8.photobucket.com/albums/a1/hey124/RIMG0008-4.jpg
Once the jubilee clips and bushes are in place the ties and
spring clamps can be removed;
http://i8.photobucket.com/albums/a1/hey124/RIMG0009-3.jpg
Then position the washers and spring for fitting.
Now the fun begins!, I start pressing/hitting the assembly in
from the bottom of the casing, Once the top bush is engaged in
the casing the jubilee clip can be removed from around that one,
Leaving the clip on the lower one;
http://i8.photobucket.com/albums/a1/hey124/RIMG0010-2.jpg
Then I keep hitting the assembly all the way to the bottom
jubilee clip, Same with this one, Once engaged I remove the
clip, And continue hitting the shaft all the way home;
http://i8.photobucket.com/albums/a1/hey124/RIMG0011-2.jpg
Then I replaced the seals in the end caps;
http://i8.photobucket.com/albums/a1/hey124/RIMG0012-2.jpg
The bronze thrusts are then slid along the shaft, Into the
casing;
http://i8.photobucket.com/albums/a1/hey124/RIMG0013-2.jpg
Followed by the end caps, Fitted with new gaskets & a smear of
hylomar if ya like;
http://i8.photobucket.com/albums/a1/hey124/RIMG0014-2.jpg
http://i8.photobucket.com/albums/a1/hey124/RIMG0015-2.jpg
Replace and tighten all the bottom end cap screws, On the top
cap only replace two of the screws, And fill the unit with oil
using ep 90 through the missing screw hole, One to fill the
other to let air out, Then, once full of oil replace the screws
and tighten .
Job done!;
http://i8.photobucket.com/albums/a1/hey124/RIMG0017-1.jpg
http://i8.photobucket.com/albums/a1/hey124/RIMG0016-2.jpg
Now just fit it to the chassis using plenty of anti-seize!, And
re-fit the steering arms ;D.
Cheers, Jack
#Post#: 5131--------------------------------------------------
Re: How to rebuild a steering relay.
By: Calum Date: January 16, 2012, 7:25 pm
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Very good! I like the way you compressed the spring. I struggled
with a 10-minute version of the special tool listed in the
workshop manual. I need to make a proper version of the tool
ideally. After all the messing about trying to get it all in
with the tufnol bushes, I left out the steel washers :@ They
shouldn't make all that much difference in all honesty, but if I
do get round to making a proper tool I'll strip it down and fit
them.
#Post#: 5150--------------------------------------------------
Re: How to rebuild a steering relay.
By: Willy Eckerslyke Date: January 17, 2012, 4:07 am
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Very useful post. I have one that needs doing and was wondering
how. So thanks!
#Post#: 5163--------------------------------------------------
Re: How to rebuild a steering relay.
By: Jackual Date: January 17, 2012, 5:15 am
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Thanks! :D I followed an ancient set of instructions that was
with a NOS relay shaft, This was the tool they used.
I think you'll be pretty safe, Calum, With out those steel
washers, Its not as if the spring or bushes move, Just the relay
shaft itself.
[quote author=Willy Eckerslyke link=topic=226.msg5150#msg5150
date=1326794875]
Very useful post. I have one that needs doing and was wondering
how. So thanks!
[/quote]
Thanks, Glad you found it of use 8)!.
#Post#: 6678--------------------------------------------------
Re: How to rebuild a steering relay.
By: Harry2a Date: January 23, 2012, 11:21 am
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Great thread, Pillow case is a good idea, avoids loosing that
part that you saw roll under the bench, yet isn�t there when you
look! Usually the rarest bolt known to man.
#Post#: 97304--------------------------------------------------
Re: How to rebuild a steering relay.
By: Fluffle-Valve Date: April 27, 2015, 2:02 pm
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Good detailed write up. Thanks for that.
http://www.series2club.co.uk/forum/forum/Smileys/default/tiphat.gif<br
/>
I was wondering how people did this task and now I know. :-?
#Post#: 97312--------------------------------------------------
Re: How to rebuild a steering relay.
By: Snailer Date: April 28, 2015, 3:04 am
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excellent write up. thanks for posting.
#Post#: 98162--------------------------------------------------
Re: How to rebuild a steering relay.
By: poprodder Date: June 27, 2015, 11:24 am
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great write up, very informative.
cheers.
#Post#: 102819--------------------------------------------------
Re: How to rebuild a steering relay.
By: Correus Date: May 15, 2018, 4:30 pm
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Hello -
Do you still have the pics of the tool you made out of a pair of
clamps to refit the spring?
Thanks!
#Post#: 102872--------------------------------------------------
Re: How to rebuild a steering relay.
By: Jackual Date: August 25, 2018, 5:23 am
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Photos seem to be working ok? I know Photobucket went a bit
weird, but seems ok now :-?
Cheers, Jack.
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