S3 109 Safari project......

GSF 109 · Apr 10, 2021

Hopefully will get assembling some new shiny bits as I’m fed up cleaning off rust and grot!

Wagon Loon · Apr 10, 2021

Wow, that was nasty inside and out, good job decrudding

GSF 109 · Apr 10, 2021

Ha, ha, yeah, I’m getting a bit fed up of cleaning but needs must! I used some Jizer in a big tub and let them soak for a while first. Looking forward to getting some paint on it tomorrow....

mick the builder · Apr 11, 2021

Nice to see you cleaning and using old parts instead of just buying new and fitting. Anyone can do that.

GSF 109 · Apr 11, 2021

Thanks, I’ve tried to use as much of the original vehicle as possible. I could have replaced the chassis too, but I reckoned that there’s was enough of it sound enough to save! The axles and gearbox are original, so I have tried to repair what I can. All the wear parts are available and relatively inexpensive. Kind of satisfying too!

GSF 109 · Apr 11, 2021

Managed some painting tonight. Think the diff and the swivel housing bits look a bit fresher.....

GSF 109 · Apr 11, 2021

While the paint was drying I started on the n/s half shaft. To say the u/j was toast would be an understatement!

GSF 109 · Apr 11, 2021

Next, I stripped off the spacer, inner race and collar. Then, dismantled the u/j with a press. You can see the collar is grooved where the seal sits and the inner race is extremely worn, so they definitely needed replacement......

GSF 109 · Apr 11, 2021

After a really good cleanup, I inspected the shaft and apart from some surface rust, it is in really good condition.

GSF 109 · Apr 11, 2021

I picked out one of my new old stock universal joints, re-greased the needle bearings and pressed them in. It’s a great feeling using nos parts rather than buying ‘new’. What a difference! Nice and smooth movement with no binding or tight spots. After that, I fitted the new spacer, inner race and collar. The half shaft is ready for another tour of duty

. Just hope my wife doesn’t notice the bath towel is missing

GSF 109 · Apr 13, 2021

Back on to the swivel hubs now...... fitted the lower steering arm, o ring and swivel bearing.

GSF 109 · Apr 13, 2021

I fitted the shims for the top swivel and it took a couple of goes to get the preload correct. It needed 2mm of shims to get it right which seems to be quite a lot.....

GSF 109 · Apr 13, 2021

Just got the finishing touches to go now. I sealed the seal and retainer in with blue hylomar just to be sure. Don't want any future leaks!

GSF 109 · Apr 13, 2021

The eagle eyed might see that the brake pipe retainer is not fitted. I just haven’t gotten round to painting it yet! Once it’s painted I will fit it...I also need new nuts for the swivel hub to axle connection, however I just used the old ones until the new ones arrive.

GSF 109 · Apr 14, 2021

Got my u bolts fitted on the driver’s side today. Took a week and a half to arrive from Paddock. Better late than never!

GSF 109 · Apr 14, 2021

Replaced the front diff pinion seal too. Surprisingly, the castellated nut was only finger tight!

GSF 109 · Apr 14, 2021

Next time, I will start on the backplate ready for assembling the brakes etc....

mick the builder · Apr 15, 2021

Slowly getting there.

GSF 109 · Apr 15, 2021

mick the builder said:
Slowly getting there.

Yes, it’s taking a long time to clean and paint everything before I can even think about bolting shiny bits back on. I want to do it right, but it is frustrating!

GSF 109 · Apr 17, 2021

Got the diff gasket through in the post today so managed to get the diff back in.....

S3 109 Safari project......

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