Ugggg!

Piston damage

Loads of pock marked - erosion - on piston crowns

Absolutely knackered piston crown on #3

I need a new set of pistons

(No great shock)
1965 series 2a station wagon piston damage1.JPG
1965 series 2a station wagon piston damage2.JPG
1965 series 2a station wagon piston damage3.JPG
 
The electrickery is back on.

Bell end Turkish knob head had been using bell wire extension leads and blown the circuit breaker so the rest of us didn't have any power for nearly two weeks as the land lord was off elsewhere...

...so nice having mains electrickery. Got right on it with the angle grinder. I cut the bolts off the front axle's swivels. Rust had won the day - so cutting was the only way =>

1965 series 2a station wagon front axle swivel bolts cut off1.JPG


1965 series 2a station wagon front axle swivel bolts cut off2.JPG


Got the front differential off too.

It looks really nice!

1965 series 2a station wagon fron differential removed1.JPG


1965 series 2a station wagon front differential removed2.JPG


1965 series 2a station wagon front differential removed3.JPG


I'm gonna see if the engine builders place I use will chuck the axle casings in their commercial washing machine...
 
Waste of time

I found an advert for some BHB new pistons - 20 thou over sized too - got all excited. The web site where the advert was advertised sent an automised message warning me about this seller saying he might not be in Holland when I contacted the seller so the olde alarme bellse started to ring...

...turns out the old coot is in Holland but probably of German perhaps Polish descent. Lives in a very wealthy area. I now know how the old bugger got his money - pure meanness!

Advert said new.

Turned out to be used.

Turned out to be very used with broken piston rings. Lots of pitted rust damage.

Old git started to argue with me on my first in take of breath and he didn't let up.

Insisted on showing me more rusty junk - saying it wasn't his fault the stuff was rusting - that there was nothing he could do about it...

...I didn't even bother to let him into the little secret of covering exposed engine parts in grease. Lost cause.
 
Yesterday I did a bit.

Got the front differential a bit further along.

1965 series 2a station wagon front differential strip down1.JPG
1965 series station wagon front differential strip down2.JPG


I think I've ordered the bearings from 'addocks - I'll have to check my order though. Got to find my bearing removal puller kit first though.

(Being organised is everything!)
 
Rear differential is in much better condition

1965 series 2a station wagon rear axle removing axle shafts and differential1.JPG


I understand that using a three legged puller to remove the driving plate bit isn't always necessary!

1965 series 2a station wagon removing rear axle half shafts and differential2.JPG


Special tool for the axle bearings is a must - much better than the hammer and chisel method used by the "expert mechanic" shown previously in the thread - tosser...

1965 series 2a station wagon removing rear axle half shafts and differential3.JPG

Oil is dirty - but minimal rust - which is good! =>

1965 series 2a station wagon removing rear axle half shafts and differential4.JPG
1965 series 2a station wagon removing rear axle half shafts and differential6.JPG


Locking wire on the bolt heads on the inside of the axle housing has gone west...

1965 series 2a station wagon removing rear axle half shafts and differential7.JPG
 
No great shock

Front differential is a wee bit buggered. I'm going to replace the small differential cogs and the bearings which are toast.

Luckily the pinion and crown wheel looks like they're OK

1965 series 2a station wagon front differential a wee bit stuffed1.JPG
1965 series 2a station wagon front differential a wee bit stuffed2.JPG
 
Front propshaft is getting new universal joints. One end was seized. Needle bearings all rusted out.

After removing the circlips I pressed the caps out with a hydraulic press by moving the UJ cross piece within the ends of the yokes so the caps came out.

1965 series 2a station wagon dismantling front propshaft1.JPG


On the back end of the propshaft I was lucky with the circlips. The front end ones were rusted and so broke off in the yokes. That took a bit of jiggling by pressing the caps inwards a bit so I could pick out the broken circlip pieces.

1965 series 2a station wagon dismantling front propshaft2.JPG


The picture above shows (I think!) how the outer side of the yoke is being supported by some sockets and that I'm using a larger socket on top that is big enough inside the socket for the cap of the UJ to pass within

1965 series 2a station wagon dismantling front propshaft3.JPG


Picture above shows the needle roller bearings now that a cap has been removed.

1965 series 2a station wagon dismantling propshaft4.JPG

Sometimes it was necessary to push the caps with collapsed needle roller bearings inside to get the cap on the other side out (if you see what I mean? - Probably not - try it yourself and you might see what I mean!)

1965 series 2a station wagon dismantling front propshaft5.JPG

Once you've wiggled the UJ cross piece out of the way you just need to push out the last cap that is stuck in the yoke.

I didn't really need to resort to this =>

1965 series 2a station wagon dismantling front propshaft6.JPG

...but as I'm replacing everything...
 
More on the front propshaft.

Removal of the jubilee clips on the rubber bellows was hard! Nightmare - stuck - needed loads of penetrating oil and a half inch drive flat head screw driver with a grolly bar to get them off.

I really wanted to save the rubber bellows because I bet the new versions rot and fall off the propshaft after 30 minutes - whereas this original one just needs a clean and some aerospace303 to get it back into shape.

Eventually I got to this stage =>

1965 series 2a station wagon front propshaft derust1.JPG


Once cleaned I noticed a bit of play in the splines. Green book says you can have up to 1mm rotational play in the splines - I haven't bothered to set up a DTI on it just yet.

I'm gonna gamble on getting a new front yoke section. The 'addocks sell them for about 15 quid which seems like a reasonable gamble to take to me as the rear section splines look brand new.

So I'm just gonna derust the rear section (also known as the big bit)

Using the cheapo drill wire brush junk from silverline so I don't gouge out big lumps by accident =>

1965 series 2a station wagon front propshaft derust2.JPG


Rustyco treatment after a bit of degreasing with brake cleaner =>

1965 series 2a station wagon front propshaft derust3.JPG


An hour later after a rub down with some wire wool =>

1965 series 2a station wagon front propshaft derusting4.JPG

It is now back under a new layer of Rustyco gel to clean up the last bits before I start with a thin layer of Ferpox undercoat.
 
Bad news on the front differential again =>

Axial bearing came off the crown wheel side alright...

1965 series 2a station wagon front differential pulling off axial bearings1.JPG


...unfortunately the rust has gotten to the other side...

1965 series 2a station wagon front differential pulling of axial bearings2.JPG


...I can try and cut the inner part of the bear away from the housing but I have a feeling there will probably be corrosion damage underneath...

1965 series 2a station wagon front differential pulling of axial bearings3.JPG


...I'm hunting for a replacement differential to see if that will end up being a more economical solution
 
Bad news on the front differential again =>

Axial bearing came off the crown wheel side alright...

View attachment 103058

...unfortunately the rust has gotten to the other side...

View attachment 103059

...I can try and cut the inner part of the bear away from the housing but I have a feeling there will probably be corrosion damage underneath...

View attachment 103060

...I'm hunting for a replacement differential to see if that will end up being a more economical solution
Try ...paginamarkt.nl theres usualy someone on there with stuff or try vandamrhenen.nl he,s got loads of diffs
 
More paint applied!

Front propshaft back bit in primer
1965 series 2a station wagon front propshaft derusting5.JPG


Pulley on crankshaft in satin black.

I've used Eastwoods extreme chassis black for this. I'm not sure about the original colours - anyone know if that's about right?

1965 series 2a station wagon front crankshaft pulley painted in satin black.JPG
 
there is another guy in rotterdam called ron bollenboom but i cant remember his address!!! he,s always selling bits on paginamarkt.....if you get real stuck PM me
Thanks I've heard of him too.

I think I've just bought a second hand one from a chap called Arend who does Land Rover and jeep parts. He's also in the Randstad area of Holland so I'm trying to get it sent by post. Bloody long drive for just a differential.
 
Ah good you are doing stuff! Looks like it's moving in the right direction overall.

At the weekend I did a Land Rover thing, I took the mostly fallen off door completely off the Discovery :D
 
Ah good you are doing stuff! Looks like it's moving in the right direction overall.

At the weekend I did a Land Rover thing, I took the mostly fallen off door completely off the Discovery :D
Thanks Dan,

Are mostly falling off doors normal on Discovery's? I've heard bad bad - oh so bad - things about Freelanders but thought the Discovery's were a bit better...
 

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