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OK - So the theme here appears to be that we really need to be completely sure that it is absolutely full of oil, and perhaps it might not be quite there yet. I'll remove a bottom bolt (just to check that things are wet at the base of the unit) and take off the top ones again to see if I can...

Yes - There's a lot of traffic on the web about filling these things with oil. My approach was to simply take two bolts out of the top and fire oil in from my little oilcan into one hole until it stopped bubbling at the other. I used 1.5 oilcans full, so I picked it was full up at that point...

Hi All I've just bought a N.O.S. relay for my S3 rebuild and having carefully installed it, find it is way too stiff. I can swing it around using a 500 mm lever, but using anything shorter is a real effort. Way more than the 12 lb I'm aiming for. The manual says if the action is too stiff...

Thanks guys - I think I have a source for a second hand front one, so I'll see if I can get one there. Cheers Andrew

Got my S3 88" propshafts down off the shelf at the weekend to clean them up and install new UJs, ready to go back on the vehicle at build time. Turns out that they are both the same length. Now the book says that the front one should be about 50 mm longer than the rear on a shortie like mine...

Hey thanks guys. I have now located a chap close to me here in NZ who has rebuilt a bunch of these boxes and he's agreed to look through my collection of parts and tell me what else is knackered. I've checked out the Shop4Autoparts site and they look like they know what they are doing, so...

Here's a couple of photos of the 3/4 synchro clutch from the side, as suggested. The inner teeth are all different widths! So this unit has got to go. I tracked down an outfit called T.A.S in Italy who apparently manufactures these for various suppliers, including Britpart. T.A.S seem to have...

Thanks guys. I temporarily fitted the end of the mainshaft into the overdrive bearing yesterday. It felt snug with no play, so I guess that's a bonus. I'll give it a further clean up with a wire wheel as James suggested and see how I feel. A new mainshaft isn't the end of the world, even...

Thanks for that advice guys. I've had another look at the various components and decided that the transfer case end is all good enough to be reused as-is. There was a bit of light surface rust on the intermediate gear but nothing that didn't clean up with emery cloth and no pitting on the...

Here are (hopefully) a few pics of most of the moving parts. By my reckoning, I need a new 3/4 synchro clutch, the little teeth look pretty sad on that. New baulk rings wouldn't go amiss and also the gears for 1 and 2. It's the little teeth that look the most knackered, but they don't look...

I'll sort through and get some pics of the worst looking stuff and post them later on.

Did you get the original tub underfloor cross members hot dip galvanised, or were you able to buy new in that state?

OK - Finally got both the boxes stripped and everything labelled in little zip lock bags. So far so good. Now the various manuals all say things like 'inspect and replace worn parts'. This is all very obvious when something is broken or in my case missing completely (synchro flat spring - fell...

I'm going for the Pollack changeover solenoid on my twin tanker petrol. I plan to use a DPDT switch on the dash to changeover both the fuel solenoid and the fuel gauge senders so that the sender on the 'live' tank is the one that the fuel gauge reads from. The simple three-port solenoid fuel...

OK - Finally got the boxes stripped and everything labelled in little zip lock bags. So far so good. Now the various manuals all say things like 'inspect and replace worn parts'. This is all very obvious when something is broken or in my case missing completely (synchro flat spring - fell out...

I have exactly the same issue with my S3 which has had S2a hubs fitted in the past. (Also a S2a gearbox and an ENV rear axle, but they are other stories). My drum stud holes are a bit tight for M16, but I'm picking there's no major issue with drilling them out a touch bigger? My hubs have...

Thanks for that. I've just cut my LH tray off because I'm fitting a second tank under the passenger seat. Mine was in remarkably good condition, so I may stick it on Trade Me. It'd be a good replacement for someone whose tray has rotted out.

No - the intention is to tidy, not polish! Some bits were pretty tired - unsurprisingly given she was a farm vehicle for 20 years, but she is straight, which is great.

I'd love to join you in the Series, but she's all scattered about the workshop at the moment! Cheers Andrew

Here she is as trailered up from the farm (seven hour journey over an alpine pass on a heavy trailer = LOTS of diesel!) She's now in bits. I repaired the chassis - normal stuff - outriggers, rear X member, a few cracks. Send it off for galvanizing. Did the bulkhead at the same time. It was...