Giving an old S3 army girl a new lease of life

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A good afternoon spent on the old girl.
Had a look at a very murky looking fuel pump.

Having taken it off, disassembled it, cleaned it all down and put it back together it looks much better.

I then thought that I'd have a go at the water pump because everything under the bonnet looks rusty and grim.

It cleaned up really well.

Ready to replace with a new gasket.
 
Well done on getting that off ok :) the two bottom bolts on my 2.5 sheared which was PITA to sort out as it was a timing case off jobby.

Yours seems to be coming along nicely :)
 
Had a go at getting the brake bits off the bulkhead today.

A very murky looking master cylinder.

disconnected all the hydraulic pipes and took the nuts off from the servo but it won't shift. Any ideas?
 
Managed to release the servo from the bracket but it won't shift. Any ideas.

Tried removing everything else.

Keep learning all the time. It now makes sense how the brake lights work!!

 
Still can't get my master cylinder and servo off. How do you get the brake pedal off. I've tried hitting the middle bit to release the pedal but it doesn't want to move. What am I doing wrong? Looks like a nice little puzzle for New Years day.

Happy New Year to all LandyZoners!
 
That pin in the middle should have a split pin through the little which looks like its out in that pic. You just knock that pin through and the servo seperates from the brake pedal :)

Lucky you on having a series brake tower! Rare as hens teeth apparantly! Why I had to modify a 110 one to fit :)
 
I love it when I'm lucky and have no idea why! Makes all the hard work worthwhile. I'm going to hit that middle pin hard and see if it moves.:mad:
 
I hit the pin hard and it came out!

Then I got the master cylinder off.

So my servo is now ready for an overhaul.

My rare brake tower which was stuck on tight (is there a gasket for this?)

Brake pedal out.

All the bits ready for cleaning and overhauling.

The hole in the bulkhead.


Unfortunately rain and wind stopped play, as well as visiting relatives!!!;)
 
Worth taking the pedal spindle out and cleaning up whilst you have it stripped that far.
should be a lubricating bolt in spindle which can be replaced with grease nipple for future use.
 
Thanks, Blackburn, any advice like this as I go along is invaluable. Nothing is going back on until it is as good as it can be. However, I'm trying not to change anything to keep it as original as possible.
 
Had a great afternoon today. Got the clutch and cylinder off and the steering column and box. This was a bit of a bugger as the drop arm wouldn't release from the rocker shaft but it eventually moved with some brute force and ignorance. I've just finished degunking it and reassembling ready for storage. Pictures to follow.
 
Don't like the idea of shelling out £21.69 each for the gaskets between the brake/clutch boxes and the bulkhead from WAPSIPURT. I've just ordered a sheet of 1.5mm neoprene rubber for £2.50 and will try to cut my own. Can anyone see any problems with this?
 
Here we go. The story of my day.
Having removed the brake box a couple of days ago, decided to take off the clutch and the steering today.
Faced with this......

Fixing bolts came out quite easy.

Then took the pipe off (maybe easier doing it the other way round!!)

Came off quite easy, leaving a rather rusty hole in the bulkhead.

Pedal and unit seemed fine.

Today's first question. The master cylinder looks very corroded. They seem quite cheap on ebay. Is it worth replacing whilst the old girl is in bits or should I stick with the original?
 
I then moved onto the steering column. All books and general wisdom suggest removing the steering wheel first. However I discovered that I don't have a socket big enough so ignored the general wisdom.......
First I removed the fixing bracket on the bulkhead.

Then the clamp came off.

Then, due to not removing the steering wheel I lossened everything else I could find!

I then removed the end plate, realising that removing the oil first may have been a good idea! I also discovered a wide selection of steel, plastic and paper gaskets/washers.

I then started on the side cover plate as I hoped that by now all the oil had found a new home over my drive.

It had and the inside looked nice and shiny.

As I have said before, this whole thing is very new to me so I was slightly surprised when a shower of silver balls started bouncing across my drive!

I now know that they were a combination of balls from the main nut assembly and the adjustable ball race.
The side plate had a milled washer stuck to it when I took it off. I now know this to be the roller off the end of the main nut which moves within the groove.

I'll gather my thoughts for a bit and continue my tale shortly!:)
 
The next bit was a total bugger. I fought hard to remove the nut from the end of the rocker shaft.

But the drop arm just refused to budge. I assumed that it should just slide off but it wasn't shifting.

Ultimately I turned to brute force and smacked it with a mallet and it shifted, allowing me to remove the steering box and expose the business end of the steering column.

The bulkhead was now looking very bare.

And that bloody awkward steering box was in the yellow box awaiting cleansing!

I then needed to remove the steering column so had to figure out how to get it through such a small hole......

I just made it bigger!

So ended up with this.

And the old girl is looking very bare!
 
I cleaned all the bits down with petrol and they came up quite clean.


And started to look at reassembling.

This can now be stored ready for replacement once I start put bits back on rather than just taking bits off!
 
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