Sweden - Gambia

[SilasStingy]

Thanks Rick, will check the bearing!

The frontbumper repair is done now, cut out the angles with laser the rest was improvisation, this will do for now until I build a proper bullbar.

I don't know, think I will keep posting what will be done on the car and other plans and questions regarding this trip to Gambia on this thread, I know it's under "mods" and most of it is I guess but there is also technical parts... Thought it might be fun to keep it in one place for anyone who like to follow this particular story!

Anyway, here goes some pics from the bumper repair, the old man helped me here.

The damaged parts:

Angles:

Welding!

The result, just need some black paint!:

 

[SilasStingy]

re diff leak grab hold of the shaft on that side and check for even the slightest up/down movement if it moves then the bearing is stuffed, Rick

There is indeed some play in the bearings, on both sides... Thinking the best would be to take out the diff and work with it on a bench instead if fiddling about under the car. Do you happen to know the size of the bearings?

 

[jims-terrano]

Good luck and I like what you have done with the bumper brackets:thumb2

Have you checked out the downloads section in the quick links? Alsorts to help you in there.

 

[SilasStingy]

Yep, have printed most of the workshop manuals to keep them in the car! This Terrano is really taking plenty of brain power these days. I'm happy for each night dreaming of something else than the car haha...

 

[solarman216]

There is indeed some play in the bearings, on both sides... Thinking the best would be to take out the diff and work with it on a bench instead if fiddling about under the car. Do you happen to know the size of the bearings?

no I do not, but they are taper roller adjustable with shims on the housing insert, but they will need looking at and checking first for damage, they should not have worn to the point of play as they have a preload, so something else must be wrong, no oil or water contaminated oil comes to mind, Rick

 

[rustic]

Re CPS Audi A3 from Motorseamus on Ebay, Rick

I bought my last NGK glow plugs from them, very good supplier, I phoned him first to check stock, excellent ebayer, based in Belfast I think, but next day delivery fantastic.:thumb2

 

[SilasStingy]

no I do not, but they are taper roller adjustable with shims on the housing insert, but they will need looking at and checking first for damage, they should not have worn to the point of play as they have a preload, so something else must be wrong, no oil or water contaminated oil comes to mind, Rick

Hmm, ok.. I recently changed the oil and I have seen and done several oil changes in various gearboxes for heavy machinery on screens and conveyors in the mining industry. And this oil was among the worse I've seen. Smelled and looked like something that comes up the day after a long night out!

 

[SilasStingy]

Well now to something less important but every little progress is still progress!

The holders for the sidesteps are now sandblasted and powdercoated, this one is smoking hot directly from the oven :naughty

Does anyone have an idea of the best way to make the sidesteps nice and shiny again?

 

[solarman216]

Hmm, ok.. I recently changed the oil and I have seen and done several oil changes in various gearboxes for heavy machinery on screens and conveyors in the mining industry. And this oil was among the worse I've seen. Smelled and looked like something that comes up the day after a long night out!

your diff could well be beyond repair, take it out and have a look, but I will not hold my breath, I have several in the UK but I guess shipping will be expensive, Rick

 

[SilasStingy]

That's what I'm afraid of, hopefully this weekend I will manage to bring it down. As for other threads on this forum it seems like it might or might not be possible to fit a diff from a earlier model? A bit confused on this subject.
Winter will soon come here and during that time I will not move the stick from 4x4. To drive with only 2wd (rearwheel) around here is not to recommend! Frontwheel drive is just fine...
Therefor I'm thinking it's essential for the diff to match to prevent windup?

 

[solarman216]

Diff from earlier model will fit, and as far as I know the ratio's are the same all the way down the line for Diesel's, petrol's are slightly different ratio, but having said that yours being in Sweden could have a different ratio, so it would be helpful to know the number of teeth on the crown wheel and pinion, Rick

 

[SilasStingy]

I still haven't had the time to remove the diff. Been traveling back and forth to south of Sweden, a journey of about 2000miles so I know the car better now, at least on the tarmac! It runs great so most off my worries are gone.

What do I need to remove to convert it into a 2wd for the time being?
Diff - Front prop - drive axels?
Anything else to think about?

 

[solarman216]

but your

I still haven't had the time to remove the diff. Been traveling back and forth to south of Sweden, a journey of about 2000miles so I know the car better now, at least on the tarmac! It runs great so most off my worries are gone.

What do I need to remove to convert it into a 2wd for the time being?
Diff - Front prop - drive axels?
Anything else to think about?

as you have fixed hubs the best way is to just remove the front prop, 8 bolts, that is all, but your front diff will still be turning so not a lot of gain except you will be able to select low box in two wheel, Rick

 

[SilasStingy]

I was just thinking if I can remove the diff while I try to inspect/repair it and continue to drive the car while the diff is taken off? I'm trying to sell my other car atm so this is the one and only!

 

[solarman216]

Mmmm OK so you can drop the front diff and front prop but as you have fixed hubs the front shafts will continue to turn ( not good) you cannot remove the shafts without exposing your wheel bearings to debris, you cannot remove the hubs for the same reason, I have not seen manual hubs so am blind on this but would assume that you can remove the internals and re fit the hub outer in order to keep debris out and not be connected to the shafts, Rick

 

[SilasStingy]

Ok I see, not as easy as I thought... Seems like if I have three options. 1st, just forget about the diff issue and live with it as long as it works (keep on filling oil in it). 2nd, go for a new diff and hope that the ratio is the same, or hope for my boss to be in a good mood when I ask to borrow the company car for a while

 

[solarman216]

Having thought about it the fixed hubs have the shaft circlip on the outer, so no it will not work, you need a pair of auto hubs without the internals but need to transfer the circlip from the outer grove (fixed hubs) to the inner grove (Auto hubs), but to stop slack you will need the thrust washer and inner cone from autos if you cannot source these I have loads, or in fact any large washer to take up the will do, Rick

 

[SilasStingy]

Okay thanks for the info Rick! I have booked a 4 post car lift today for 6 hours. I'm hoping to be able to remove the diff, inspect it and mount it back again during that time. A bit nervous, if I fail there will be no car to drive home in the evening haha. Pictures will be posted!

 

[SilasStingy]

Long day it was.. 8h of work. Removal - Inspection - Running around town scavenging for parts - Installation. Couldn't get the right oilseal so leak will still remain. Ordered some seals before but they didn't fit. Same type but too big. At least I now know that it doesn't look too bad inside. A bit of play in the bearing but I think it will survive for some time.
Seemed like the breather was clogged so cleaned it, that might be the reason for the bad oilseal!

Ratio is: 36/8= 4.5 (I saw that Banshee had 35/8 so maybe I counted one too many, not a big difference in any way, was way too tired at that time haha!)

Work in progress, the old man helping me here again!

The bad oilseal:

ID number:

 

[SilasStingy]

Today I decided to do something constructive, mounting three 75w xenon extra lights! The ballasts are fairly big so it took me awhile to find the perfect spot. The bulbs will arrive next week so will mod three Bosch big knick reflectors and the night will become the day!