Clutch Fitted

New bolts on the flywheel all torqued up.

New HD clutch.

New clutch cover.

Corrosion Protection

Spent a bit of time going round the engine bay using "BlackIt" spray on the chassis, bulkhead where the clutch box is going to be fitted and then all the seams around the bulkhead tunnel arch.

There were a few old screw holds in the back of the bulkhead. Filled these and rounded off with SikaFlex. Once set, I'll spray over with BlackIt.

Flywheel Housing

Bolted on the flywheel housing.

Hylomar sealant applied.

All torqued up and off the stand.

Took the copper main shaft bearing out from the crank shaft. Filled the end with heavy duty grease and drove in the clutch alignment tool. Hydraulic pressure from the grease pushed the bearing out. Crazy pressure generated for sure. New bearing is soaking in engine oil overnight and will fit

Made up a tool to gently drift in the new copper bush back into the crank shaft. Put a bolt into a socket whose outer diameter matched the inner diameter of the bush, washers tightened up with a nut to socket head and then lock nuts on the end to protect the thread. Gently tap into place.

Cylinder Head

Engine block all cleaned up ready to fit the cylinder head.

Check the raise of the cylinders above the cylinder block. Validating the correct thickness of the new head gasket.

All confirming that a 2 hole gasket is required.

Cylinder 1 - Front 65, Rear 60

Cylinder 2 - Front 65, Rear 63

Cylinder 3 - Front 64, Rear 64

Cylinder 4 - Front 61, Rear 52

Nice and shinny.

Dowels, gasket, thermostat and coolant elbow fitted. 

New head gasket.

There are 4 sequences in total. Torque and 3 sets of angles on specific bolts in each sequence. 

Fitted the vacuum pump, oil filter housing, manual fuel lift pump and oil breather. All these parts were cleaned up prior to fitting with new gaskets. New washers for the sump and coolant plugs too. New injectors, fuel lines and spill returns fitted, glow plugs and push rods. All new copper seals as necessary.

Fitting the rocket shaft.

Valve clearances setup.

Loaded up with air intake brackets, engine breather, coolant pipes, fan, brake vacuum hose, new spill hoses. 

Transmission Rebuilding

 Order a new heavy duty clutch release bearing mount.

Heavy Duty clutch 

Clutch release bearing is on hold due to new clutch fork hole for push rod clamp not being in exactly the correct location causing issues. Will send back and get another. Rebuilt the transfer box and main gearbox selectors and attached to gearboxes. 

Rebuilt transfer box selector.

Main gearbox selector.

All the linkages attached and tested.

Fitted the new rear shock absorber mounts to the chassis.

Heavy duty clutch fork and heavy duty release bearing fitted.

More work on the under carriage

Meant to take an image of the sleeve on the transfer box.

To quote from Ashcroft Transmission website:

"The hole that supports the head of the intermediate pin in the LT230 casing is prone to wearing, and the pin elongates the hole so that it is out of round. This can lead to a transfer case whine, and an oil leak. Using our CNC lathe, we turn a stepped bush from EN24T steel. We mount the casing in our CNC mill, and machine an oversized hole on the correct centre and press the steel bush into the housing."

Added the transfer box gear selector rods. Fitted with new plastic bushes and clips. Also the breathers with new copper washers.

Fitted new rear bump stops. One thing to note is that there is a ridge that is offset on the back. This needs to be matched correctly into the chassis.

Fitted with new flanged bolts, nuts and washers.

Fitted a PCT adjustable towbar.

Needed a bigger torque wrench to fit the M16 bolts.

 

Fuel tank all fitted with guard and hoses with new clips.

Transmission Rebuilding

Ordered some grease for the inner of the clutch release bearing. Workshop manual stated that it needs to have Molybdenum Sulphide.

Clean up the transmission brake drum and the compressor. Cleaned up the pads and inner brake surface with brake/clutch cleaner.

Thankfully the bolt alignment ensures that it can only be fitted in the correct orientation.

Went to fit the speedo worm gear. However, noticed that the stud had been removed by Ashcroft Transmissions

Will have to order a new stud. Also, need to renew the O rings. 

Spent some time trying to identify this bracket. Turns out that this mounts to the bell housing to keep various cables under the chassis tidy.

Could not resist upgrading to a heavy duty clutch release bearing.

It weighs an absolute ton and feels the business.

Dismantled the transfer box lever mechanism. Renewing the O rings and various bushes.