853 replies to this topic

[timmy850]

Good to see you getting some progress here 

I haven't been very productive, the cars been broken a month now! Hopefully it'll be sorted soon..

I got a new mirror today. It's a Raydot replica, which were also called Downton mirrors.

The door looked like this with the old mirror removed. I'll get another rubber grommet to block up the second hole

And installed



It bolts into the front window catch

I've also got all the bits to rebuild the diff with the HS joints. One of the planet gears is a bit loose on the diff pin so I'll need to chase that up. I made a little progress today and removed the uni joint from one of the HS joints, I'll need to get some proper circlip pliers to get the other one apart

[Jared Mk3]

I do like that mirror.

[timmy850]

I do like that mirror.

Thanks! Makes me wish there wasn't holes in the door already though..

I've got the universal joints stripped down and ready for new inner bearings. They got a coat of paint too!


The diff has been pulled apart ready to be rebuilt, and I've also got some red engine paint to redo the engine and gearbox. I'm not sure whether to repaint the rocker cover too (it was originally blue) with some wrinkle paint or leave it as bare alloy.

[Vinay-RS]

Those look like new! 

[timmy850]

Those look like new!

It's surprising what a coat of paint does sometimes! They're all done now with new universal joints and rubber boots

[Jared Mk3]

I wouldn't mind a set of these. Looking good there!

[timmy850]

I wouldn't mind a set of these. Looking good there!

I have got another set around that needs a rebuild... They'll probably be going on my 1100 engine. It's handy that they share the same driveshaft splines so that I don't have to swap them either (the pot joints have different driveshafts). This is how they looked when I got them


I've got a replacement planet gear on the way which should turn up tomorrow..

[Jared Mk3]

Great job you've done. I may have to persuade you at some stage

[StewartB]

Love this car, i really do and with that engine out give a good excuse to tidy and paint   lovely motor!

[timmy850]

Great job you've done. I may have to persuade you at some stage

Cheers, I'll be very happy once it's all back together again. I haven't decided for sure what to do with the spare set of HS couplings, I'll let you know though.

Love this car, i really do and with that engine out give a good excuse to tidy and paint   lovely motor!

Thanks! It's another one of those jobs I wish I didn't have to do, but I may as well clean up the engine bay while I'm at it.

Here are all the parts from the rubber cross joints except the castellated nut and split pin. Preferably your u-bolts will be nice and straight!

And these are all the bits you'll need to swap to Hardy Spicer joints. They have larger diameter diff side covers than the rubber cross and pot joints. It's also a good idea to swap the planet gears, diff pin and diff bearings while you have it all apart.

I'll see if I can weigh both sets as a unit to compare the rotating mass between them..

Edited by timmy850, 25 February 2015 - 03:36 AM.

[Jared Mk3]

 

Great job you've done. I may have to persuade you at some stage

Cheers, I'll be very happy once it's all back together again. I haven't decided for sure what to do with the spare set of HS couplings, I'll let you know though.

 

I'd appreciate it 

[timmy850]

The diff pin and pinion washers were worn in the current diff...

And so was the diff cage.

I stripped down the 3 other diffs I had and this one looked in good nick. I've found a nice pair of output shafts to go along with this. Hopefully I can build it all up on the weekend.


One of the other diffs was even more worn the my current one!

[timmy850]

The new diff gears and pin have been installed into the diff cage.

The crown wheel and bearings were done next. I've measured the diff tolerance and ordered the shims to get the diff installed this week hopefully.

I also cleaned up the diff housing and regreased the shift mechanism.

The remote extension was pulled apart, cleaned up and regreased too. I had to use a replacement extension as the old one had stripped the thread for the gearshift locating pin, and there shift rod had a bit of wear in it too.

While it was apart I also cleaned and regreased the gearshifter. It has a nice smooth action now when moving through the gears.

The outside of the engine is getting a quick spruce up while it is out. A lot of the paint had already peeled off the engine block. It is getting a couple of coats of red paint so hopefully it’ll look a bit tidier under the bonnet...

[timmy850]

The engine has come up nice and shiny with a few coats of red. The camera phone doesn't capture the colour like it looks in person. I was a bit lazy with the masking so there is a little overspray to clean up  

 

It took me a while to get the diff shims all sorted (mainly because it took me an hour or so to finally find a set of feeler gauges) but I got there in the end.

 

The diff side covers and shift linkage were installed and it all moves smoothly. I've still got to get some nuts for the output flanges to bolt the Hardy Spicer joints in. The output flanges also need to be bolted to the output shafts. 

 

I got sick of moving parts around the place so I've temporarily put the manifolds and rocker cover on the engine. This rocker cover currently doesn't have a breather on it so I'm not sure if I will need to put one in. It still has the breather from the tappet cover to the air filter.

 

[Jared Mk3]

Looking good mate