 | Home > Maintenance & Modifications > Shaggydogs Running Restoration |
 
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| Ellisboy Member Since: 13 Oct 2013 Location: Deep South Posts: 539  
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 nice job,looks good. |
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1st Jan 2015 8:56pm |
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| g-mack Member Since: 07 Jan 2014 Location: northumberland Posts: 1967 
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looking good !! im in 2 minds wether or not to take my panels out and fit windows for the dogs hmm decisions...... My 109 thread
my youtube channel |
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2nd Jan 2015 11:07am |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347 
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Thanks Guys
I'm quite pleased at the moment though still waiting for my parts to turn up to try and sort out this juddering issue. G-mack: To be honest I think you would regret it putting windows in, they leak, rattle and are so insecure I'm so glad to be rid of them. Plus you have a 300Tdi utility wagon, its quite a rare vehicle! If you wanted a CSW version they are a pound to a penny but you have got a very nice and very desirable vehicle to begin with. Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter  |
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2nd Jan 2015 5:02pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Right!
Day started well with strong cup of tea, trip to the bottle bank to drop off the last of the new years excesses and a cup of tea for when I got back. Anyway, the task was to change out the drive flanges with new replacements to try and eliminate some drive line slop and a strange judder on start off. So what do we need.....  Click image to enlarge I grabbed a 17mm socket, Ratchet, Torque Wrench, Soft mallet, Circlip Pliers, Gasket, Drive Flange, and bolts which I didn't need. (off to a good start already) Click image to enlarge So what are we looking at? The rubber cap in the centre of the hub is pulled off in order to get to the circlip securing the half shaft. There are many ways to remove it but I just gave it a sharp tug to remove. Click image to enlarge The circlip exposed, unclip it and put it somewhere safe and clean. Click image to enlarge Humm all looks a bit gappy in there, not the worst I have seen but noticeably sloppy. I could get quite a fair bit of rotation. Not sure what the significance is of W9? Anyone? Click image to enlarge The bolts were cracked and withdrawn. This is where I noticed that due to mine being an earlier model it has Bolts and spring washers!  Oh well I suppose this is better anyway!
Click image to enlarge The flange removed, it then gave me access to scrape the mating surface clean. The threads were cleaned out using a m10 tap. Note the length of the halfshaft sticking out.... Click image to enlarge This is where it all started to go a little pear shaped. New gasket lubricant was applied and the new flange was offered up. I hadn't realised quite how tight a fit it was so as I tryed to press it on, I felt the shaft slide into the axle, and then a click. Humm, not sure what that meant. So I tried to pull the halfshaft out so I could fit on the workbench....It wouldn't come out. Mild panic set in, wrapped a cloth around it and gave a sharp tug......Nothing. Panic well and truly set in as I need her for work tomorrow and cant afford the down time - let alone the damage caused by it being exposed overnight! What to do- Cup of tea and think Click image to enlarge The cup of tea lead me to think why not drain the axle, remove the rear diff pan and then stick in a podger and poke the end of the halfshaft back out and free! Brilliant! And I could install my new rear diff pan and change the oil win win! So, oil drained and all bolts loosened. Click image to enlarge Ahah.....A Salisbury differential. Thats nice. Good Its still there...........Well thats about all I can do from here. Half shaft still stuck.  .
So few phone calls later and a cup of tea and it was revealed that you can poke a long stick through and push it out the other side. Click image to enlarge So, I'm doing both sides anyway so the other end was inspected. Again stamped but this time W7? Click image to enlarge And then removed completely. Note the half shaft has been completely withdrawn. Click image to enlarge I found a piece of copper tube and gave it a good clean to make sure it didn't have any grit or stuff which could contaminate the inside of the diff or axle casings. 1 sharp tap with a mallet and.... Click image to enlarge Pop! much to the surprise of Dad who was digging over the flower beds "is it meant to do that?"  "yes dad, its ok"
So weight released from my shoulders, carry on as you were! all be it some 2 hours later! 
Click image to enlarge The new gasket was placed onto the new drive flange with a smear of gasket lube. Click image to enlarge The halfshaft was again withdrawn and inspected, looks fairly good so it was given a liberal coating of copperslip and then the drive flange was tapped onto it (making sure to keep a firm grip on the halfshaft to stop a repeat of what happened above. Click image to enlarge Hooray were getting there! Click image to enlarge Bolts were given a good dose of copper slip and torqued up to 70nm Click image to enlarge The rubber cover popped back on. The next few shots are missing as I was trying to get this done quickly! The mating surfaces were cleaned and degreased, the bolts wire brushed and copper slipped and the new gasket installed along with the new diff pan. This was then topped up with some EP90 (2.7L worth at ruinous expense from Halfords! )
Click image to enlarge Tada! Note its now dark! Test drive revealed no bad noises or rumbles and nothing got hot so all is well. The judder remains which is annoying, but at least I can now safely say apart from the input flange the rear axle is sound for the next few years! She then got a wash down to clean up any grease or oils and to remove quite a lot of road dirt! No photo I'm afraid because its dark but she did look good in the evening dusk! Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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11th Jan 2015 8:37pm |
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| JAY BOY Member Since: 04 May 2010 Location: Not here Posts: 1706 
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Another great write up Fella.
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11th Jan 2015 8:55pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Not much to report of late.
She had her 6000 mile oil change 2 weeks ago and is already 600 miles closer to her next one. Have fitted and now wired up a Aux fusebox in the battery box which should make fitting any future electrical toys a bit easier and took some feeds off the battery post which were a bit......dubious. Other than that just the usual squeaks and rattles to remind me I'm moving or stationary. I need to sort my rear exhaust section, despite it only being replaced last Christmas it has already rusted into a state and has now found a new game of "fall off the exhaust mount and rest on the mud flap!" Jobs to do are: Carry on sound proofing and cleaning the interior. Fit a small sub to improve the radio noise. Thinking about a cubbybox to expand my switches. Fit and plumb up my Webasto Fit my LED Strobe Lights Continual Running maintenance. I'm still looking for a PTO winch - Preferably a ex-utilitys hydraulic one so if anyone has one I'd be interested to hear from you
Otherwise, she is doing well 
Click image to enlarge Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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15th Mar 2015 6:07pm |
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| steventheplumber Member Since: 29 Apr 2014 Location: Lincolnshire Posts: 767  
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Try Marcus he does a lot of ex military stuff, nice chap as well www.marcusglenn.com
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16th Mar 2015 8:53am |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Well my tightening of my exhaust clamp worked in a fashion but the rattle returned today.
I knew it was too good to be true and on closer inspection I found that the clamp that mounts to the clamp is......broken. Looks to me like the bracket on the exhaust isn't in the right orientation. So when it was bolted up tight everything bent and then over time it moved and then cracked and broke. Click image to enlarge Click image to enlarge Click image to enlarge Click image to enlarge Anyway, a new one of those is ESR266 which is £14 from Land Rover and weirdly cheaper than britpart 
I will order one and then when it arrives will remove the exhaust, clean it all up and rebuild it properly. Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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22nd Mar 2015 9:36pm |
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| steventheplumber Member Since: 29 Apr 2014 Location: Lincolnshire Posts: 767
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It seems strange that it is metal on metal with no rubber sandwich in between?
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23rd Mar 2015 11:18am |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Bit of an update.
Unfortunately our family dog is very unwell and has been rushed to the dog version of intensive care. We can't help or do anything so have been trying to occupy ourselves. Firstly I nipped down to RCV in Staplehurst to pick up some rubber sheeting and spray on glue. This was then cut and liberally applied to my rear arches which had previously been fitted with sound proofing disks and thermal insulation. Due to my slightly preoccupied demeanour I didn't manage any "in-process" photos but here it is fitted. Click image to enlarge Click image to enlarge Click image to enlarge Still not sure what to do with regards the sides. Part of me wants to carry on up to the cappings, part of me wants to leave it bare. I'll see if I can find some plain untextured rubber to use for the sides but not sure. The roof needs to come off again to fit the galvanised cappings so might wait until this is done before finishing it finally. Once this was done (which makes it sound like a simple 2 minute job - took about a hour each side!) I had a go at fitting my utility panel stiffeners which I hadn't got round to fitting. Still unfitted but I did fettle them so just need some glue and they will be ready to go on which will conclude my utility conversion! Then splashed around some Tollys Creaping Crack Cure to try and get rid of the trickle of water on my right leg which has been intermittently greeting me on rainy days. All in all quite successful. Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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28th Mar 2015 8:29pm |
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| g-mack Member Since: 07 Jan 2014 Location: northumberland Posts: 1967
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Looks good
more importantly I hope your dog gets well soon My 109 thread
my youtube channel |
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28th Mar 2015 8:40pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Thank you
You wont believe how difficult it is to cut rubber sheeting with all your fingers crossed Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197
Self confessed mileage hunter |
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28th Mar 2015 8:46pm |
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| steventheplumber Member Since: 29 Apr 2014 Location: Lincolnshire Posts: 767
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That job is on my to do list as well, what thickness rubber did you use and was it expensive?
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29th Mar 2015 1:17pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Its 3mm rubber so quite nice and thin and easy to work with but its not so thin it wont offer any benefits. To be honest any thicker and your just carting more weight around and with the insulation below it it is already helps with keeping the noise down.
I got a 1.2m x 1.2m piece cut off a roll from RCV Staplehurst with a can of spray glue (which I used a whole can of ) for £26.28 but I did pick it up, though I'm sure its not beyond them to post it.
Having had a short road test now it has made a noticeable difference. Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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29th Mar 2015 3:23pm |
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| shaggydog Member Since: 12 Aug 2012 Location: Kent Posts: 3347
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Bit of a slow day today.
Started off by topping up the Gearbox oil - another 250ml since Jan so might have to start looking at getting a new box on order as replacing the seal is a very much involved strip down process! Checked the engine oil which is still fine so thats good, power steering has lost some but not enough to worry about, but worryingly the coolant level had dropped by nearly 500ml which will require some very careful monitoring. Once the usual checks had been completed I set to it and sikaflex gun in hand to fix in the Tophat Strengthening sections to complete the Utility wagon conversion. Still gluing as we speak 
Click image to enlarge Click image to enlarge Looks a bit Heath Robinson but due to the nature of the panels they need to be pulled onto the Tophat Sections where needed - hence the varying positions of the hooks. Some cheep self adhesive hooks from B&Q were the ideal for pulling the flat interior surfaces in against the glue! All looks a bit messy at the moment but once everything is dry and the excess removed it will all be cleared up and painted and hidden away by insulation and sound proofing will be great! Once the glue has set can finish of the painting and the sound proofing in the rear and it will be done! Other than that having a good poke and prod and just general nose around and check of the condition of everything which has revealed all the paint on everything under the chassis is looking a bit tired. I don't really have the time or the patience to repaint everything underneath so does anyone have any ideas on where to get it done? Running Restoration Thread http://www.defender2.net/forum/post323197.html#323197 Self confessed mileage hunter |
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5th Apr 2015 8:01pm |
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