S3 109 Safari project......

GSF 109 · Nov 5, 2023

Fitted up the flywheel housing with a new gasket, along with the flywheel all cleaned up, the 9.5” diesel clutch and discovery pressure plate.

GSF 109 · Nov 5, 2023

After a bit of blood and lots of swearing, I finally managed to get the engine in. Not an easy job on your own but got there. Nice to see that the spacers on the passengers mount have done the job and lifted the turbo above the chassis with decent clearance

. Been at least 7 years that there was last an engine in the chassis. Next up, the gearbox…..

LincolnSteve · Nov 6, 2023

That is some important progress. Nice one.

GSF 109 · Nov 7, 2023

Cheers….5 years in….5 years to go…

. Let’s hope not anyway.

Plan is to get the gearbox in with new seals and gaskets and oils, then refurb the propshafts, fit them and probably back onto bodywork after that. Some light at the end of the tunnel now…

GSF 109 · Nov 27, 2023

Decided to take the plunge and have a look at the gearbox over the weekend. First thing to do was strip out the slave cylinder and clutch release arm. With that, it became clear that the slave cylinder had been a slave cylinder too long! I could not believe the amount of gunge and corrosion built up inside and around the cylinder. Maybe it’s original to the car, but it was definitely needing replaced.

I took off the actuating rod, clutch release arm and fixings, cleaning them up as I went. I bought a new old stock Unipart release bearing, which fitted perfectly after cleaning up the nose that it slides along with emery cloth and lubricating with copper grease. Fitted a new slave cylinder, swapped over the bleed screw fitting from the old to the new, and gave it all a clean up with a wire brush on a drill.

GSF 109 · Nov 27, 2023

Moving on to the leaky oil seals, I stripped off the front output shaft drive flange and housing, cleaned it all up, replaced the seal, gasket and refitted with a new split pin. It was a doddle, so moving on to the handbrake drum, I removed the drum to be met with a gungy mess!

Time for some new brake shoes I think. After this, I ordered some new old stock brake linings, so that will be a job for next weekend along with replacing the offending leaking seal and a real good cleanup!

GSF 109 · Dec 9, 2023

When I stripped down the brakes, the adjuster was completely seized, so I ordered up a new one. It was a ‘county’ make which seemed to be decent quality and a good fit too. Just the same price as Britpart. I also stripped, cleaned and rebuilt the expander mechanism. What a faff that securing clip is! Talk about making something difficult when it could be made simpler! After coating all the sliding surfaces with copper grease, it all seems to be working perfectly.

GSF 109 · Dec 9, 2023

GSF 109 said:
When I stripped down the brakes, the adjuster was completely seized, so I ordered up a new one. It was a ‘county’ make which seemed to be decent quality and a good fit too. Just the same price as Britpart. I also stripped, cleaned and rebuilt the expander mechanism. What a faff that securing clip is! Talk about making something difficult when it could be made simpler! After coating all the sliding surfaces with copper grease, it all seems to be working perfectly.

GSF 109 · Dec 9, 2023

After stripping the shoes off, I put them in the vice and chisled off the old friction material then sheared off the old rivets. Cleaned them up and gave it a light dusting of black paint to smarten them up a bit. I love the fact I have new old stock linings which are oem manufactured and fitting them onto original shoes. It’s also considerably cheaper than buying inferior new ones. I haven’t riveted shoes for many years so it’s good to try out old skills

….

GSF 109 · Dec 9, 2023

Next up was to assemble everything back together and fit it to the transfer box. I made a gasket and used some sealer for the oil thrower. I cleaned the brake drum with thinners, abraded the brake surface and gave the outer a coat of paint. Coming together now

GSF 109 · Dec 24, 2023

Next up was fitting the gearbox onto the engine! couldn’t wait to get another big bit fitted

.
Was a bit of a faff though, due to the weight and trying to do it myself…. After calling in the cavalry 2 hours later it was in, within 15 minutes

. I fitted two new gearbox mounts along with new fixings. Felt like a big step forward!

GSF 109 · Dec 24, 2023

With this initial success, I thought I would push it a bit and look at the handbrake lever and mechanism. I had a pick of three levers. Somehow I seem to have collected a trio of them, and none of them very pretty! I gave the best one a bit of a wire brush by hand but it needed more, so I moved onto the bench grinder with the wire wheel but that was a fail too…. Next up was the blast cabinet which worked a treat. The factory black paint seems to be very hard wearing and nothing else could touch it.
After a blast to bare metal, I cleaned down with thinners, followed with three coats of primer and two coats of black gloss. Not too shabby now in my opinion

. All that work on something no one will even take notice of…..

GSF 109 · Dec 24, 2023

After fitting the lever, I found the relay and rods, stripped and cleaned them. A going over with the wire wheel on the bench grinder, I primed and painted the relay with satin black. I checked the centre wear bush and it was in good condition. I had a new pivot pin, so after a good coat of copper grease I fitted it into the relay. I had a new pivot already in stock, and a good used one, which I cleaned up and refitted. Unfortunately I don’t have the shim or nut to secure the relay, so that will have to wait until the new year when PA Blanchard delivers them

. Think I will move onto the propshafts next to clear some more stuff of the garage floor!

Wagon Loon · Dec 25, 2023

GSF 109 said:
After stripping the shoes off, I put them in the vice and chisled off the old friction material then sheared off the old rivets. Cleaned them up and gave it a light dusting of black paint to smarten them up a bit. I love the fact I have new old stock linings which are oem manufactured and fitting them onto original shoes. It’s also considerably cheaper than buying inferior new ones. I haven’t riveted shoes for many years so it’s good to try out old skills ….

I didn't know this was a thing. Thats a great job

Wagon Loon · Dec 25, 2023

GSF 109 said:
After fitting the lever, I found the relay and rods, stripped and cleaned them. A going over with the wire wheel on the bench grinder, I primed and painted the relay with satin black. I checked the centre wear bush and it was in good condition. I had a new pivot pin, so after a good coat of copper grease I fitted it into the relay. I had a new pivot already in stock, and a good used one, which I cleaned up and refitted. Unfortunately I don’t have the shim or nut to secure the relay, so that will have to wait until the new year when PA Blanchard delivers them . Think I will move onto the propshafts next to clear some more stuff of the garage floor!

Youve really got some ground covered, Hope the origional gearbox is up to the job

GSF 109 · Dec 25, 2023

Wagon Loon said:
I didn't know this was a thing. Thats a great job

Thanks Wagon Loon - yep, when I was an apprentice fixing lorry brakes, truck owners didn’t like spending money. They would ask me to fit brake linings instead of buying complete shoes as it was a fraction of the price

. Didn't know that you could get linings for Landrovers until I found these! Great option though

GSF 109 · Dec 25, 2023

Wagon Loon said:
Youve really got some ground covered, Hope the origional gearbox is up to the job

I hope so, but I have it on good authority that as long as you don’t abuse the box, it will last.

Wagon Loon · Dec 25, 2023

They're tough boxes if your patient between changes I believe

GSF 109 · Dec 31, 2023

I moved onto the front propshaft, which isn’t a job I was really looking forward to! I bought a pair of new GKN branded uj’s and one, new old stock Unipart which is actually made by GKN as I found out when I opened the box. I prefer GKN uj’s as they seem to fit well and last too.
I hammered out the old joints, cleaned all the mating faces up, smeared some grease on the cups to help them on their way and pressed the joints in

.
It still needs some work on the sliding yoke to make sure it’s okay, then a clean up, some paint and a greasing… then do it all again on the rear.

GSF 109 · Jan 7, 2024

Did some catch up on some of the unfinished jobs today. The parts for the handbrake linkage arrived from Blanchard, so I cracked on with that, fitting a new clevis, spring, relay pivot pin washer and spring retainer. I greased up the moving parts and put it all together and adjusted it. One more job ticked off the list

S3 109 Safari project......

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