Oliver and Colin's 1960 Series II rebuild.

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red90
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Re: Oliver and Colin's 1960 Series II rebuild.

#101 Post by red90 » Sun Apr 01, 2018 5:56 pm

Or...the shaft may be installed back to front.

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cbalme
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Re: Oliver and Colin's 1960 Series II rebuild.

#102 Post by cbalme » Sun Apr 01, 2018 8:13 pm

The locating Pin is installed in the second hole from the front of the engine. There is no hole in the rocker shaft for the locating pin to thread into at the front but the locating pin at the back was already threaded in and lined up. This pin is in between cylinder 3 and 4. So I suppose this means the shaft is installed backwards. It should work either way, shouldn't it?
Colin

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Re: Oliver and Colin's 1960 Series II rebuild.

#103 Post by red90 » Sun Apr 01, 2018 8:48 pm

cbalme wrote:It should work either way, shouldn't it?
I'm not sure. If it is completely symmetrical, it should not matter. It looks like it, but I can't guarantee it.

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Re: Oliver and Colin's 1960 Series II rebuild.

#104 Post by cbalme » Mon Apr 02, 2018 9:23 pm

It seems as though there is an oil return and entry gallery from that video so it should work either way. I think I will use it the way it is and take my chances.
Colin

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Re: Oliver and Colin's 1960 Series II rebuild.

#105 Post by cbalme » Tue Apr 03, 2018 10:46 pm

Well I did another valve set and found one adjuster to be of concern. Is this a sign of bad things or is it normal? It is screwed in very far compared to the others. I checked the pushrod and it is straight and compared to another push rod they're the same length.

The photo is of #6 adjuster, which was adjusted when #3 valve was open.

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The push rods from the old motor are slightly longer compared to the ones from this motor.
Colin

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Re: Oliver and Colin's 1960 Series II rebuild.

#106 Post by red90 » Wed Apr 04, 2018 6:58 am

Are the valve heights the same? Rocker bent?

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Re: Oliver and Colin's 1960 Series II rebuild.

#107 Post by The_Anachronist » Thu Apr 05, 2018 6:42 am

Yeah with an engine that old I’d bet on valve height. All mine were about .25” short - and with not much zip left in the spring.
1963 S2a 109 Station Wagon, restoration started Oct. 17, 2015.

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Re: Oliver and Colin's 1960 Series II rebuild.

#108 Post by cbalme » Thu Apr 05, 2018 10:26 pm

The valve heights seem about the same compared to valves near #6

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The next thing I'd suspect would be something to do with the cam and followers. The plan is to rebuild the Solex 40 PA in the next few days and see if the engine will run. Then I'll decide from there what to do.

I have been making progress in other places like the steering and Air filter. It's a lot of painting to make things look nice and tidy. The steering box is in very good shape it just needs a new gasket to solve a leak.

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Air Filter installed

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Colin

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Re: Oliver and Colin's 1960 Series II rebuild.

#109 Post by cbalme » Sun Apr 08, 2018 11:02 pm

Got a bit of work done today on the old Series, refurbished the Solex Carb and got it back on the Motor. Very close to firing it up and seeing if it actually runs!

My Grandfather and I tore the carb apart and cleaned it up and reassembled it with a kit. It was missing some parts so we just cleaned and reused the old ones.

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Then without anything else left to do I decided to bend up the brake lines for the rear axle. I used my hand to bend the lines so it's not very pretty. The lines are longer than they need to be which is annoying.

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Colin

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Re: Oliver and Colin's 1960 Series II rebuild.

#110 Post by cbalme » Thu Apr 19, 2018 10:17 pm

We've finally got around to putting the gearbox back together. Victor came over last afternoon to give us a hand.

Here we are pressing first gear on to the layshaft. They had to remove it and take all the wax off. I'd left it on which turned out to be a bad idea.
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Pressing the bearing on to the primary pinion. We made sure to the washer on the other side as per the manual. The previous time it was apart someone put the washer on the wrong side.
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We then put the primary pinion into the bellhousing. We had a hell of a time trying to pound the bearing in so we used a heat gun to warm the bellhousing for 5 minutes then it just fell in. It was quite comical how easy it was compared to before. We used the same trick for the layshaft bearing and tightened up all the studs and bolts that held them in.
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Getting the gears ready to go in. at the time we had the layshaft assembled in the wrong order but we figured that out later when the Syncro wouldn't fit beside the gears
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Didn't take many photos of the assembly since it required many hands but it went together without too much trouble. The biggest issue was lining up the layshaft with the main shaft but after a bit of fiddling, we got it to go. The gear that matches the primary pinion was put on at the same time as the bellhousing and primary pinion since it was the only way we could get things to align.
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We called it a night after we got the gear selectors aligned. We ran it through all the gears and none of them grind so it is ready for the transfer case and final reassembly.
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Colin

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Re: Oliver and Colin's 1960 Series II rebuild.

#111 Post by cbalme » Fri Apr 20, 2018 11:14 pm

Did a bit of fiddling with the gearbox tonight. Hopefully I'll have it done by next week.

I only got the reverse springs installed tonight. It was missing one so I just changed them both while it was apart.

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Colin

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Re: Oliver and Colin's 1960 Series II rebuild.

#112 Post by cbalme » Sun Apr 22, 2018 1:05 pm

I got bored Saturday night and decided to put the box back together. I finished it up this morning and just need to put the slave cylinder back on then it's done.

I adjusted the clutch release pin with the 7/16 drill bit and bolted it back on. I also put the top back on with some grease to hopefully seal it.
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Then shimmed up the transfer case, it didn't need any extras it was already perfect.
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After that I mated it all together. I put the intermediate shaft in before the gearbox output gear which was a mistake so I had to take all of that apart again.
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Put the springs in for the gears and setting the clearances with the adjusters
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Just a few more things then it's ready to go back in!
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Colin

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Re: Oliver and Colin's 1960 Series II rebuild.

#113 Post by cbalme » Sun Apr 22, 2018 11:35 pm

I was expecting to be able to put the box back in the truck this afternoon but found a crack in the pipe that connects the slave cylinder to the throwout assembly.

You can just make out a hairline crack beside the hole for the pin. Above is the galvanized pipe we used to make a new one.
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Our reamer was broken so I had to file it out by hand which took quite a while. Eventually, I got it to fit as it should with a new grommet in place.
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Put a shiny new slave cylinder into the housing I found in my parts pile that was nice and clean. I will adjust it later one I get the hydraulics installed.
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I also cleaned and degreased all the mounts so I can paint them.
Colin

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Re: Oliver and Colin's 1960 Series II rebuild.

#114 Post by ANDYD » Mon Apr 23, 2018 10:37 am

Great progress Colin, I'm feeling a bit guilty having left my project for a few weeks and watching all your good progress.

So regarding the gearbox, now that you put it all back together, did you find a lot of wear and tear on gears or bearings or were the replacement parts more just to change them while you had it on the bench? I'm at that point where I am going to change all my seals, but not really seeing any wear or excess movement in the bearings or gears.
Reluctant (or lazy) to just change bearings for the sake of it .... hummmm...
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Re: Oliver and Colin's 1960 Series II rebuild.

#115 Post by cbalme » Mon Apr 23, 2018 8:11 pm

Hi Andy, good to hear it is still being worked on. With this gearbox my original plan was to just change all the gaskets and seals but I crushed that rear layshaft bearing by accident so I had to take it all apart. After disassembly 1st gear was found to be in bad shape so we changed it out. Other than that all the gears were in good shape. It's very easy to change the bearings if you have a heat gun and a freezer or access to a shop press. We changed 3 out of the 5 bearings inside the gearbox because they were easy to deal with even though they were in good shape. We left the rear mainshaft bearing because it was in perfect condition and reused the old bearing that goes between the mainshaft and the primary pinion because the new britpart bearing had more play.

I didn't change any transfer case bearings I just took it apart and cleaned it. When you go to put everything back together just shim it all and make sure it's set to the correct preloads and that sort of thing.

Overall I would just give the whole box a good look over and change anything that looks overly worn. I'd also talk to Victor or Matt who are quite good at this sort of thing.
Colin

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Re: Oliver and Colin's 1960 Series II rebuild.

#116 Post by cbalme » Wed Apr 25, 2018 12:13 am

This afternoon we got the gearbox installed. It was very fiddly and took a while to line everything up but then it all just slid into place.
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I was having troulble aligning the mounts and it turns out I put the removable cross memeber on the wrong way round. Once I got that sorted out it went into place quite well
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Then I put the handbrake on with a bit of siliconce on the mudshield. The shoes were easy to put on on the bench with older springs
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Then I torqued up the flange, put the drum on and adjusted the handbrake to how it should be.
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Also made a new cork gasket for the filler hole on top. It took two tries and turned out okay.
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Next job is putting the propshafts on and then onto welding the bulkead!
Colin

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Re: Oliver and Colin's 1960 Series II rebuild.

#117 Post by cbalme » Sun May 06, 2018 10:19 pm

It's been a busy week without much progress on the Land Rover.

Propshafts got installed last weekend with new bolts.
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Bought a battery that was an inch too long so I had to trade it for another. Getting closer and closer to firing it up!
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Found out that Land Rover makes two carburettor elbows, one is for the Solex on the left and the other is for a Weber or Zenith on the right. You can slightly see that the one on the right is slightly bigger. So I had to paint the other and not use the nicely painted one I already had. Now it's all connected and the old vacuum advance I found in the parts bin is hooked up.
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I also got a vintage Jack-All from my grandpa which will suit the 109 quite nicely.
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Colin

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