Restoration

Technical questions and answers
map1275
Posts: 1076
Joined: Mon Jul 21, 2008 2:48 am
Location: Brisbane, Australia

Re: Restoration

Post by map1275 »

The etched part number and advertising inside the hub is a nice touch.
Cliff4WD
Posts: 303
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Well I now have a nice new pair of balls 😂

Image
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS
disco2hse
Posts: 1637
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: Restoration

Post by disco2hse »

An excellent rundown. Thank you.
Nice trick with the solder too. :idea:
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5
Cliff4WD
Posts: 303
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Next up, Final Drive Unit aka Front Diff

Image

Image

Image

First, I gave it a good wash. Initial inspection all looks great, can't see any signs of wear. I need to measure pinion to crown backlash as there is movement but don't know if it's within tolerance, so need to get a dial gauge.
I have a new oil seal and mud shield to fit in the meantime.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS
Cliff4WD
Posts: 303
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Dial gauge arrived so wasted no time in using it to check crown wheel run-out and crown/pinion backlash.

Image

Backlash was spot on spec at 0.15mm (image shows it zeroed)

Image

Looking closely at the overall condition of the final drive unit, I think that it must already have been rebuilt or a refurbished unit fitted. The crown and pinion and the differential all look like new. This all fits with the known part of the vehicle's history i.e. being rebuilt on galvanised chassis and the RPi engineering rebuilt engine.

I masked off the gears and wire brushed the case...

Image

...applied rust converter

Image

...and painted with my favourite chassis paint

Image

Should be able to reassemble and put it all back on the vehicle next week.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS
Cliff4WD
Posts: 303
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Today is refit front springs and axle case day.

Step one was hang the springs on front hangers

Image

Then re-seat axle casing on the springs and loosely fit new U bolts

Image

Image

Then jack up to bring the shackles in line with the mounting bushes and loosely bolt in place

Image

Image

Image

Torqued up the u-bolts to 58lbf but left the shackle bolts loose until spring height is set. Have to reassemble the rest of axle first.

That's enough for today as all the struggling to line up and get bolts in took longer than this post might suggest.
User avatar
firemanshort
Posts: 378
Joined: Fri Feb 10, 2006 2:42 pm
Location: Loudoun County, VA - near Wash DC

Re: Restoration

Post by firemanshort »

Just to ask.... why did you not reassemble to whole axle on the bench where it is easy to reach and then put tires on it and wheel it under the frame for re-install. I did that with mine and it worked very well because the tires "jacked" or held the axle in position.
-----------------------------------
Firemanshort
Image
Virginia, USA
Cliff4WD
Posts: 303
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Ah well now, I'm doing a disc brake conversion but don't have the caliper mounts yet, also the wheels need to be bigger to accomodate the caliper when on but I haven't refurbed the ones I bought or fitted tyres yet. So, not able to roll it into place. It's a bit heavy fully assembled hence the staged approach I'm taking, as I can better manage on my own this way. I'm also a bit pushed for space so really want to get as much back on and out from under my feet; I'm tripping over the gearbox, V8, and axle all sat on the workshop floor. I plan to take the roll off/roll on approach for the rear when I get to it, assuming I don't kill myself getting the tub off the chassis first. :shock:
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS
Cliff4WD
Posts: 303
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Talking of Disc Brake Conversion, 2 boxes arrived this morning.

Pair of brake calipers, pads, mounting plate conversion, extended studs for hub, fixings, and brake pipes.
Image

...and a pair of discs (rotors)
Image

The caliper mounting plates are well engineered and bolt onto the swivel housing on top of the stub axle
Image

So bolted on the RH swivel assembly
Image

Image

Image

Had to stop and give the stub axle a good clean and check the bush and seal. I was going to fit a new seal but the bushes seem to be made of unobtainium, so I've paused for the moment while I consider my options. I think the seal looks ok as it happens so don't want to destroy the bush getting it out if I don't need to.
The other job I need to do is clean and refurbish the hubs. Also, I have to remove the studs and fit the new extended ones. They look to be pressed in and the hub peined over to lock them in place. Oh well, at least they're not welded in!
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS
disco2hse
Posts: 1637
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: Restoration

Post by disco2hse »

This will be interesting to watch.

Last lot of studs I replaced, they just bashed straight out.
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5
DeRiecroft
Posts: 9
Joined: Mon May 04, 2020 5:41 am

Re: Restoration

Post by DeRiecroft »

This is amazing, and I absolutely love the detail you have gone into for the novices like myself! I have currently taking ownership of a 1983 stage 1 with the V8, the bulkhead has a fair few rust spots and I was debating just replacing it but after seeing the effort and the after shots of yours, you have convinced me that it can be done! I will be coming back to this thread a lot over my rebuild.
CROFTY

:arrow: 1980 Stage 1 V8 109” 2 Door
:arrow: 2010 Discovery 4 TDV6
Cliff4WD
Posts: 303
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Well, it's nice to know it's of use to someone. I often think I'm just boring everyone by teaching Grandmother to suck eggs.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS
Cliff4WD
Posts: 303
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

What a Feckin disasterous day today. Needed to refit the final drive unit (diff) so that I can refit the half shafts and CVs, so that I can carry on and fit the caliper mounting brackets. Double checked the meshing pattern on the CW&P (perfect), cleaned both of the mating surfaces on drive and axle case, cleaned stud threads, applied hylomar blue and gasket, then discovered the 10 fastening nuts were AWOL. Spent the rest of the day tearing apart every conveivable place they might be hiding. I must have sorted through all my carefully bagged and labelled bits 10 or more times over. Crawled around the motor on my hands and knees searching, then inside workshop turning everything upside down and inside out. Absolutely no sign of them. I do not understand! Totally peed off and angry, knocked it on the head. I suppose I now have to scrape off the hylomar and get another gasket as well as new nuts! It's a holiday weekend so that's me stopped for days before I can get replacements. 😡😤
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS
Cliff4WD
Posts: 303
Joined: Fri Aug 10, 2018 2:39 pm
Location: Rye, East Sussex, UK

Re: Restoration

Post by Cliff4WD »

Found the bastards!

Image

After carefully sitting them on the chassis rail when I took them off the drive unit studs, when tidying up, seems I'd put 5 with each of the hub, axle, and brake bits. No idea what I was thinking on the day but must have forgot they were the drive unit nuts and mistook them for brake bits or something. I had meant to order new ones but forgot. Anyway, press on.

I double checked the mesh pattern of the CW&P as I found my tin of Prussian blue.

Image

Image

Image

All looks good to me.

I cleaned off the dried hyloblue from both mating surfaces on drive unit and axle case and salvaged the gasket. Applied fresh hylo and position the drive unit ready to fit

Image

It was quite awkward trying to manoeuvre it into place as it's a heavy lump, but managed to align it and push it onto the studs

Image

And put those 'nuts' on and torqued up.

Image

So, that's that back on and I can get back to what I planned to be doing.
Cliff

1981 109 V8 Stage 1
2000 Discovery 2 Td5

109 V8: viewtopic.php?f=6&t=2161
My Disco Thread: http://www.thed2boysclub.co.uk/viewtopi ... =3&t=58130

LAND ROVER. TURNING OWNERS INTO PAUPERS FOR 70 YEARS
disco2hse
Posts: 1637
Joined: Sun Apr 27, 2008 3:51 am
Location: Auckland NZ

Re: Restoration

Post by disco2hse »

LOL happens to the best of us.

Upside is, you found your tin of Prussian Blue!

:wink:
Alan

1983 ex-army FFR 109 Stage 1
2005 Disco 2 HSE TD5
Post Reply