Yet another Series 3 200TDI project

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Track rod end! Now you're talking sense at me :p
Used to them pointing towards me so it threw me a bit! I'll come back to that bit I think! Looks like it'll need all sorts to get it out
 
Can be pains to get out - but a ball joint splitter can help the process. Main reason its shot is probably because rubber boot has a hole in - water gets in and ruins the joint.

It looks knackered, so i'd be tempted to just get the angle grinder out and cut the nut / pin off..Hey presto, track rod end (minus thread..) will fall out of your drop arm.

Matt
 
Nice one cheers for that :)

Attacked the other side tonight
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It does look alot rougher than the drivers side but it seems to be literally just the footwell....

Other than that, started disconnecting everything ready to pull the lump out
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Few bolts and it should be out....busy at the weekend so that's a job for next week now :)
 
MLangford2 said:
Can be pains to get out - but a ball joint splitter can help the process. Main reason its shot is probably because rubber boot has a hole in - water gets in and ruins the joint.

It looks knackered, so i'd be tempted to just get the angle grinder out and cut the nut / pin off..Hey presto, track rod end (minus thread..) will fall out of your drop arm.

Matt
Click to expand...
fall out :rolleyes:
give it a good clout on the steering relay arm along its axis, to shock the taper. then it'll fall out.
problem you might have ( which mlangford2 might be getting at) is the amount of room required to actually get the taper and thread out of the relay arm, due to the chassis. easy to cut the old un off, but it dont help with refitting the new un. may be neccersary to lift the arm off the relay. mark the position of the arm in relation to the relay shaft first tho as the angle between the top and bottom arm should be about 81 degrees.
best of luck!
 
dr pepper said:
As you may allready know I have a 300tdi in a 109.
The exhaust fanimold is in a better position to fit, however the pressure outlet from the compressor side of the turbo fouls on the bracket for the wing, at least on mine, the 300tdi turbo has a clamp that can be loosened and the turbine/compressor housing can be rotated so the angle can be changed so as not to interere with the wing bracket.
The 200 turbo might be diffo.
The mounting bolts for the egr valve on my engine broke off, so to save faffing about I cut the sae flange of one of the egr pipe fittings welded a blank to the centre and then welded this to the fanimold using dissimilar metals welding rods, as the fanimold is cast iron, see the pic, you'd be better with a plate if the bolts do come out.
Click to expand...

Why do people do 200tdis when they could do 300s?
 
Beneagles said:
coz they are generally easier to come by...and cheaper too :)
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We bought a doner discovery for about £800, took off all the parts we needed, sold the rest without the gearbox and transfer box for £100. Looking to sell the gearbox and transfer box soon.
 
Finally got stuck in again, engine out....
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And new engine in :D in the form of 'The dude with the 110'
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Next plans is to pull everything else off the bulkhead, grind all the ****e off, then drag it up to the other building where there's power, weld it up, paint it up, and get the 200 in :)
 
Got some new lighting from work to hang up in the workshop...did away with the twin floodlights that were caning the genny and threw in a load of 5ft fluorescent fittings, much more light as well, and the gennys just ticking over really :)

Anyway.....had some helpers today.....tried to divide time between landy, my focus and the two escorts but it mainly went on the landy...
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Had 'The dude with the 110' on site again too...
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Started off by removing the battery tray and oilbath air cleaner mount, as this will foul the new engine - new battery will be mounted under the seats. Found a nice cupholder in the process as well....
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So then attacked the rear tub...
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Dude with 110 and his other half undoing the tub to crossmember bolts...
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And mine watching :rolleyes: Not bad considering shes a trainee mechanic...
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Success!
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Also removed the mouldy ****ty horrible headlining, and some of the sticky back plastic that had been applied to the inside....
Removed the remnants of the passenger door card as well, then promptly decided to remove the rusty horrible door top before it split in half and broke the glass...

Plans for the evenings of next week is going to be cleaning the chassis up mainly, and possibly having a crack at removing the roof and seatbox, if I get bored of scraping lol...

Then crack the welder out, throw in two new footwells, 2 new bulkhead outriggers and a rear crossmember.....so far nothing else has fell apart when I've tapped it with the hammer....

After that I'll coat the chassis with POR15, then start painting the bulkhead, tub and panels and throw it all back together....along with the 200TDi.... watch this space :)
 
dirtyrhino said:
that looks a little like a Sunbeam?

Good to see yer plodding on - wish I had a workshop - we've been looking around for bloody ages down here for one.
Click to expand...

Everyone says that! It's a Ginetta G26, based on alot of Cortina stuff (axles, gearbox), running a 1.6 Pinto....needs alot of TLC. It's owned by another bloke at work who wants rid of it, I'd love to take it on and throw a Zetec running twin Webers in it but I can't think of a use for it :(

The workshop is great, it just so happens that work have a huge site near my house thats mainly fields, transmitters and small workshops :) Due to be redeveloped in about 5 years so most of it is derelict, so I wangled use of the workshop :) No power unfortunately but my job involves (large) generator maintenance so we have a few portable ones kicking about.....

Todays progress was....pricing up my next order with Mr Craddock, and trying to find the money to pay for it :eek:
 
TheKeymeister said:
Everyone says that! It's a Ginetta G26, based on alot of Cortina stuff (axles, gearbox), running a 1.6 Pinto....needs alot of TLC. It's owned by another bloke at work who wants rid of it, I'd love to take it on and throw a Zetec running twin Webers in it but I can't think of a use for it :(/quote]

Track car maybe ?
I haven't seen one of them for years :eek: Unrelated, but I Used to have a 1.8 manta years ago, fitted that with twin dellorto 40's - god I loved that car.
Click to expand...
 
dirtyrhino said:
Track car maybe ?
I haven't seen one of them for years :eek: Unrelated, but I Used to have a 1.8 manta years ago, fitted that with twin dellorto 40's - god I loved that car.
Click to expand...

That could be a fair shout, to be fair I've got to finish building the Landy, finish refitting the canal boat, finish decorating the house and then sort the garden out and build a big fooking shed.....I don't think I should start anything else just yet :D

My Dad and uncle had Mantas at the same time, and as such, my nans cellar is full of Manta bits....might be worth eBaying!
 
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Did a wee bit more today, not really worth posting about because my bolt removal tool as pictured above needs TLC, but I return with questions.....mainly related to Hi-Cap differences

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Do all rear crossmembers have these type brackets on? The three inner ones have bolt-on right angle brackets but the outer ones are welded to the crossmember, from what I can see a normal series crossmember has the same brackets all the way through (same as the middle three on mine) - is this correct?

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These are my rear tub mounting brackets (at the cab end) and they're pretty knackered - one side disintegrated on removal... Are these hi-cap specific, or the same as on a normal 88/109?

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Am I correct in assuming this is a steering damper? What is its actual purpose, and should I replace it or just rip it out? It looks as seized as all the other dampers...and anything rubber thats steering related is perished anyway
 
Re assembled the flywheel and housing today, torqued it all up correctly and everything :eek:

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Seems like I've lost the bolts for the clutch cover though, and the new kit didnt include new ones, are they some sort of special high tensile bolt or just normal ones?
 
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