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#Post#: 18506-------------------------------------------------- |
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Re: Mandy |
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By: espacekiller Date: December 24, 2014, 4:11 pm |
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Gearbox, Input shaft wobbly, won't select 4wd high, and reverse |
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gate spring broken/not working. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3284_zpsd0794637.jpg… |
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stripping down in order |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3321_zps410fb443.jpg… |
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main box seperated |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3328_zpsb6ae7604.jpg… |
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Main and layshaft checking for dammage all looks new |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3344_zpsb982bd5a.jpg… |
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Checking constant gear |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3354_zps6e6586d3.jpg… |
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Play in primary pinion seemed a little excesive, check showed |
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bearing moving in case! |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3359_zps4ba0badd.jpg… |
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The root of the wobbly input shaft problem a bent bearing clamp, |
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which was not holding the bearing in place. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3365_zpscf4fdb3d.jpg… |
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All bearings bushes and gears in very good condition somebody |
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has already rebuilt this recently, just not that well |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3378_zpseb2c7fd7.jpg… |
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Checking end float on front of mainshaft, it was just out of |
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tollerance. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3384_zpsb41465fb.jpg… |
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Removing the thrust washer retaining pin, only way i could get |
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it out was to clamp it in the vice and drift the shaft upwards. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3388_zps7ae3a95e.jpg… |
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Corrected bush float with a new shim, checking end float on |
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front of main think this is 2nd. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3405_zps518821da.jpg… |
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Removing old seal as a precaution due to the wobbbly shaft. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3411_zps79a8f34c.jpg… |
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New genuine primary pinion seal |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3414_zpsaa8dcfd4.jpg… |
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Refitting primary pinion bearing with bearing retainer and new |
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undammaged clamps, like Barry Bethel it doesn't wobble anymore. |
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>Htlr< |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3417_zps8a525dcb.jpg… |
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Drifting out Reverse idler shaft after heating up case as the |
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gear had chipped teeth, probably a result of the broken reverse |
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gate which would have allowed accidental selection of reverse! |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3421_zps2bfed3b1.jpg… |
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Old reverse idler gear on right with 2 chipped teeth, NOS |
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replacement on left. Shaft frozen, main case heated and idler |
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replaced. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3427_zps8b449549.jpg… |
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Refitting Main, ensure you have the baulk rings exactly in |
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position correctly :thud |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3429_zps6582881c.jpg… |
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Rear of Mainshaft |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3430_zps7e9fb556.jpg… |
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Refitting layshaft, a bit of a fiddly job |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3431_zps5d8568c3.jpg… |
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3rd / 4th syncro unit and New main front bearing |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3434_zps0da4d7a2.jpg… |
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Constant gear and conical spacer I propped them here ready for |
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the bellhousing. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3445_zpsce9436fb.jpg… |
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and then sort of slotted the primary pinion behind it like this, |
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i found this bit tricky and frustrating i am sure ther is an |
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easier way. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3446_zpsebea4cbe.jpg… |
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Torquing up layshaft |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3449_zpsa1db8837.jpg… |
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Selector rods, new seals |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3468_zpsdfe48900.jpg… |
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Selector seal clamps |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3473_zpsfd99dded.jpg… |
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:stars at this point it all went wrong, when i tested the box |
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by hand it had a tight spot which i knew was not rite, i was |
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confused as i had been very careful. It took a couple of days of |
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thinking and spinning things by hand to work out what had |
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happened. |
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I dismantled the box again. :thud |
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I turns out the thrust washer on the rear of the main shaft is |
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very slightly damaged, it appears to have spun at some point in |
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its life against the sholder of splines which has machined off |
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about 0.40mm, just enough to cause the rear main gears to bind |
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when the rear main nut is tightened. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3476_zpscd72bc33.jpg… |
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I flipped the thrust washer over to the undammaged side and |
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checked all the clearances where OK. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3478_zpsf4dc6a2d.jpg… |
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New spring on reverse gate and adjusted up. Thats a 2BA spanner |
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the only thing i could find that fitted. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3483_zpsaa7fcd96.jpg… |
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Main gearbox finished all working smooth with no tight spots |
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>Htlr< |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3484_zps7dbad779.jpg… |
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The 4wd high would not select because this cover was crushed |
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jamming the shaft in position. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3395_zps65cfcdc3.jpg… |
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Straightened the cover and all is well with the tranfer |
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selectors. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3570_zpsfb697960.jpg… |
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All seems well with the transfer box so as they are pretty bomb |
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proof i decided to leave it alone, new genuine gearbox mounts |
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fitted. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3575_zpsdb5f2244.jpg… |
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Gearbox fitted and ready for some PAIN |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3571_zpse95dd463.jpg… |
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Gearbox recieving some PAIN |
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"All aboard Tickets please" |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/gearbox/DSCF3586_zps06e82905.jpg… |
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#Post#: 18507-------------------------------------------------- |
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Re: Mandy |
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By: espacekiller Date: December 24, 2014, 4:16 pm |
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Decided to paste all my build thread in here. more to follow |
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#Post#: 18513-------------------------------------------------- |
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Re: Mandy |
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By: towhitch Date: December 25, 2014, 5:40 am |
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--------------------------------------------------------- |
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lkebtn |
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I am about to start the physical ( as opposed to planning) nut |
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and bolt complete refurb. of my 1972 S3. I find this post very |
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inspiring, especially the bulk head work. Very well done. |
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#Post#: 18515-------------------------------------------------- |
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Re: Mandy |
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By: 2 hammers Date: December 25, 2014, 8:26 am |
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I have to say I enjoyed that. Nice pictures, good motivator. |
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Cllpcs |
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#Post#: 18524-------------------------------------------------- |
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Re: Mandy |
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By: espacekiller Date: December 25, 2014, 3:58 pm |
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Glad you enjoyed it, I love reading other peoples rebuild |
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threads you pick up loads of ideas and tips on how to tackle |
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things, stuff you only learn by doing it. I will post more over |
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Christmas to keep you going. |
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#Post#: 18526-------------------------------------------------- |
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Re: Mandy |
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By: ashcrroft752 Date: December 25, 2014, 4:54 pm |
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Looking good, I really like the idea with the washer hose and |
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cable ties. |
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#Post#: 18683-------------------------------------------------- |
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Re: Mandy |
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By: espacekiller Date: December 29, 2014, 7:27 pm |
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--------------------------------------------------------- |
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Steering relay bodged back together new spring and seals, shaft |
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and bushes reused. |
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The old shaft seal surfaces where a bit of a mess soo spun it in |
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the lathe, cleaned it up with a fine file, followed by some wet |
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and dry, not perfect but far far beter than it was. |
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new spring boing |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/relay/DSCF3485_zps22d980e4.jpg.h… |
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I dont have the correct tool and needed to press on so i did |
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this, don't do this at home ;D |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/relay/DSCF3486_zpsbc181834.jpg.h… |
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Nobody sneeze |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/relay/DSCF3489_zpsaf2d13ad.jpg.h… |
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Who's going to cut the ties. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/relay/DSCF3490_zpsf88c93eb.jpg.h… |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/relay/DSCF3492_zps2ecb1df5.jpg.h… |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/relay/DSCF3493_zps42674195.jpg.h… |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/relay/DSCF3494_zps6ef684a1.jpg.h… |
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Quick get the lid on |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/relay/DSCF3500_zps180deb43.jpg.h… |
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2BA socket fits this well nowt else seems to |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/relay/DSCF3502_zps3c812a87.jpg.h… |
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testing preload |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/relay/DSCF3504_zpsbf53fcb2.jpg.h… |
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done |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/relay/DSCF3506_zps089d0348.jpg.h… |
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The apprentice 'helped' :thud see that box with EP90 in the |
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bottom, guess where the various nuts and bolts ended up |
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:znaika[URL= |
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http://s965.photobucket.com/user/my05pjn/media/relay/DSCF3629_zpsf7d8037f.jpg.h… |
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#Post#: 18684-------------------------------------------------- |
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Re: Mandy |
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By: espacekiller Date: December 29, 2014, 7:29 pm |
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--------------------------------------------------------- |
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The engine, unknown 200tdi with 120k at �200 i took a chance. |
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My mate has been storing this for me and we have had a few |
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fettling sessions. Stripped it for inspection including bottom |
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end, all looked in good order so it was rebuilt with new seals, |
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belt tensioner and any suspect bits replaced. |
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Oil pump stripped inspected rebuilt with new seals. |
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T seas where an absoulute pig to do, I tried three times and |
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wrecked the seals every time, then i made 2 guides from a couple |
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of pieces of 40mm ally angle bent out at the top which works a |
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treat. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3612_zpse96ae9fe.jpg.… |
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New belt, tensioners, crank pulley, seals. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3611_zpsebd3a16d.jpg.… |
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Vacum pump, this sits above the skew gear which sits above the |
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oil pump, i wanted to change an O ring in here after reading |
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about a chap who killed a 200tdi because this had gone and was |
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causing low oil pressure, he also killed the rebuilt crank a |
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second time as the fault remained :eek: |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3622_zps3d2cfc9d.jpg.… |
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Skew gear fits in here |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3619_zpsbdaa1411.jpg.… |
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Top O ring, this is just to seal the body. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3616_zpsabe0fc07.jpg.… |
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Skew gear O ring, as you can see the O ring was completely shot, |
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I had a quick look and i think that the high pressure oil from |
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the oil pump must leak past the O ring as shown with the green |
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arrow then back through the open bearing to the sump causing a |
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reduction in oil pressure. |
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If you are unlucky this is not quite low enough to trigger the |
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warning light but not high enough to protect the engine, glad i |
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checked mine. |
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Top O ring ERR531 |
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Skew O ring ERR532 |
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Skew gear Gasket ETC4616 |
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|
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3618_zpsca999c32.jpg.… |
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Borrowed engine crane cheers Mark |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3633_zpsf9e53204.jpg.… |
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Can you tell this had been off roaded before i got it, just the |
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outside to clean up, it has clay baked on it wont wash off. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3634_zpsb7fa4ec2.jpg.… |
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All holes sealed up with denso tape which is ideal for this job |
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as its waterproof. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3635_zpsa422d2cb.jpg.… |
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Engine cleaned the jizzer struggled i ended up using some hope |
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*&%^$ shifter which is pretty potant (caustic) and supposedly |
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for cleaning mountain bikes, i won't be putting it anywhere near |
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mine. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3637_zps7957526b.jpg.… |
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Sometimes you wonder if it is worth it, like when your painting |
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an engine in your front garden at half past midnight. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3638_zpsa6912e0b.jpg.… |
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Next day all seems better. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3642_zps3d464b96.jpg.… |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3643_zps8be11384.jpg.… |
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Flywheel housing, note the 4 counterbored holes for cap heads at |
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the bottom. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3644_zps78ca40de.jpg.… |
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clutch centred and fitted |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3646_zps1cc65845.jpg.… |
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test fit |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3649_zps2c5c5e77.jpg.… |
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I had read a few stories of people struggling to mate engines |
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and gearboxes, so after 15mins of giggling i followed a tip and |
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fitted 4 M10 threaded rods to pull the two halves together |
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evenly, measured the gaps top bottom and sides, turned the |
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handbrake drum and it just slid together took about 3 mins once |
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the M10 rods where in :thumbs: |
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I need to cut out a lump where that clutch slave cylinder is |
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catching. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3650_zps1e29f072.jpg.… |
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The next challenge it to fit a turbo in here, the 200tdi one is |
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just never going to fit rite, but I rekon a 300 TDI one will go. |
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(or i might make one) |
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Also need to get the engine mounts in between the shackles and |
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the bulkhead support bracket, it is going to take a good coat of |
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looking at. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3653_zps50a53638.jpg.… |
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Bulkhead test fitted |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3655_zps41c0b989.jpg.… |
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Engine mount, starter, turbo, exhaust :-? |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3656_zps86ecb4f2.jpg.… |
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Out of steam for now, must catch up on some sleep. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/engine/DSCF3658_zps8e0e8a0f.jpg.… |
|
#Post#: 18685-------------------------------------------------- |
|
Re: Mandy |
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By: espacekiller Date: December 29, 2014, 7:30 pm |
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--------------------------------------------------------- |
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Working late again doing some prep work and repairs on the rear |
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tub |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/body/DSCF3632_zps93f94928.jpg.ht… |
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tub supports and side frames waxyoiled inside and out, ready to |
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lift with my helpers. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/body/DSCF3663_zps900b8f96.jpg.ht… |
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lifted on just needs positioning |
|
[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/body/DSCF3665_zps0e10aefd.jpg.ht… |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/body/DSCF3667_zps9c011fb8.jpg.ht… |
|
in position but needs more 'work' to sort a couple of problems |
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with a PO repair looking better but still lots to do. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/body/DSCF3671_zps9a108810.jpg.ht… |
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#Post#: 18686-------------------------------------------------- |
|
Re: Mandy |
|
By: espacekiller Date: December 29, 2014, 7:32 pm |
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--------------------------------------------------------- |
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As I was bolting the tub down I found this hidden by filler. |
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[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/body/DSCF3699_zps948f263a.jpg.ht… |
|
/>width=1000 |
|
height=750] |
|
http://i965.photobucket.com/albums/ae131/my05pjn/body/DSCF3699_zps948f263a.jpg[… |
|
Repair cut from a scrap Tub |
|
[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/body/DSCF3702_zpsc6e22d33.jpg.ht… |
|
/>width=1000 |
|
height=750] |
|
http://i965.photobucket.com/albums/ae131/my05pjn/body/DSCF3702_zpsc6e22d33.jpg[… |
|
Out with the old, spot welds drilled out, 1mm cutting disc. |
|
[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/body/DSCF3704_zpsc76210dc.jpg.ht… |
|
/>width=1000 |
|
height=750] |
|
http://i965.photobucket.com/albums/ae131/my05pjn/body/DSCF3704_zpsc76210dc.jpg[… |
|
Section to fit behind vertical joint to splice panels together. |
|
[URL= |
|
http://s965.photobucket.com/user/my05pjn/media/body/DSCF3705_zpsa1b2bd8c.jpg.ht… |
|
/>width=1000 |
|
height=750] |
|
http://i965.photobucket.com/albums/ae131/my05pjn/body/DSCF3705_zpsa1b2bd8c.jpg[… |
|
Rivetised using countersunk pop rivets, the plan is to fill and |
|
paint over these. |
|
Top tip of the day, if you are using countersunk rivets the |
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chances are the countersink on them is 120 degrees not the |
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normal 90 degrees, if you use a 90 countersink the rivet heads |
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deform and poke out of the top of your countersunk hole as has |
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happened here, I have filed off the excess here which is no |
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problem and bought a 120 degree countersink which gives a much |
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neater result. |
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[URL= |
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http://s965.photobucket.com/user/my05pjn/media/body/DSCF3713_zpsdcf2607a.jpg.ht… |
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/>width=1000 |
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height=750] |
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http://i965.photobucket.com/albums/ae131/my05pjn/body/DSCF3713_zpsdcf2607a.jpg[… |
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