#ZedShed Dom’s Oxford Green 3.0 Rebuild (40,000 miles)

Lee

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This is a nice treat for us at the shed. We have a rare green 3.0 with 45k on the clock in for the works. Front and back powdercoat and some subtle upgrades.

Normal service has resumed after last poor Zed so up she goes.
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Again with this 3.0 we noticed it has a 2.8 flange setup with the exhaust which makes our lives easier when removing. She’s also sporting some hearing aid beige :) also sporting some even rarer AC schnitzer hoops.
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Sporting 45k she’s in very good shape.
The engine bay looks so clean.
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Even though she has very low milage and everything is original this means nothing when it’s 20 years old. The shocks had no rebound left and the bush’s are cracked with very little support.
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So jumping back the first things we took off were the roll bars and various brackets, were going to see how the powder coaters cope with lots of little bits, We cable tied them all together so we at least know they can’t get lost our end.
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next was the exhaust system so we can get clear access to drop the subframe.
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The rest came apart very easy. So within an hour she was out. As with all our builds to save time we pre build the new arms and beam.
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then a few more minutes later everything was separated.
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Beam starting to show early signs of corrosion.
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Now everything is apart we could easily see where our smelly diff oil leak was coming from, offside shaft seal.
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thankfully they’re small change to replace and only take a few minutes.
We also managed to find a split handbrake cable, that was the highlight of the faults, she’s a very tidy Zed. While we wait for parts here’s a few underside photos.
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we’ll also be fitting some of Mazza’s tank straps to future proof this Zed.
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Stay tuned for the next update :D
 

Dino D

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Wow that’s so clean under there for 20yrs, guess it lives in a garage.

Pretty rare colour too in 3.0 form.
 
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Lee

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Nice little update. Done a few little jobs over the last 2 days while parts arrive. First on the list was the leaking diff. I keep these shaft seals in stock because it’s becoming more and more common.
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punch out the old seal.
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New seal next to the old one.
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parts compliments of BMW. I gave the diff a quick wipe down she’s so clean!
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next we stripped down the swing arms and beam. Dom requested we keep his with the car so luckily having a 2 week slot this was achievable.

old bearings bushes and hubs.
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Stripped out assembly
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These were dropped off at the coaters today.

After this we moved back under the car. We underbody sealed all the key areas and fitted some new fuel tank straps.
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such a nice fit :D

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Moving onto shiny new stuff, we collected the first lot of powder coated small bits and they look outstanding!
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We had the arrival of the briaded lines and new exhaust nuts, the old nuts really didn’t want to come off.
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The nuts look two different sizes but they’re the same. Just shows you what 20 years of road grim can do.
 

Jjim

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Mansfield
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Can’t believe how good the tyre tray came out :oops::thumbsup:
 
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Lee

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Not too much to report. Still waiting on suspension from Bilstein in Germany and the powdercoated subframe to come back. So today we did some little jobs to keep us ahead.

first off was fitting the new MTEC brakes up front along with a freshly coated roll bar with Meyle HD drop links.

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Roll bar.
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After this we did a complete fluid change. Engine oil and filters. Gearbox and diff. All the oils looked healthy and ran through our filter so nothing to report.
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After a discussion with Dom we decided to go with the powerflex bush and remove the original.
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Then to save us a few more minutes we fitted the braided lines to the rear callipers.
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still got a boot load of bits to fit. Hoping the coaters pull through and get it done this week.
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Bazza

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So leaky diff seal = clean diff =)) one clean looking zed with low miles, like shelling peas now lads :thumbsup:
 

Lee

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Another small update. We got the subframe back just in time for us to begin the rear build. I love how clean these subframes look.
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we didn’t hang about starting to fit the new bearings, shields and hubs.
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then followed the rest of the bits.

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that concluded yesterday evening.This morning we assembled the rear end ready for install. I don’t think it looked this pretty from the factory.
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Once getting to this stage we’re very close to finishing. Annoyingly the Bilstein suspension kit has been delayed, it was ordered over 2 weeks ago so Dom won’t be able to collect tomorrow. Shame as it will be ready just waiting on new suspension to arrive.
 

Rha

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That underside with all the newly renovated parts looks the dogs, I love the look of the rear diff and axle when you’ve done the powder coated frame etc, and cleaned up the diff case. Think you’ve given the Z a new lease of life, surprised at the bush deteriation on that low miler, just goes to prove that low miles shouldn’t be the only reason to buy. The bushing materials used even in the early 2000s just doesn’t stand the test of time, wonder how the new silicones etc will stand up over the same time period. Will I still be around to find out, doubt it.lol. (well done so far, lucky owner)

Roy.;)
 

Lee

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So today was a nice nearly finished type of day. The suspension kit has still not arrived. So for now we have kept the original running gear on so we can move it around it needed. She’s left on stands with the wheels off Incas they arrive in the next few days.

some snaps of the finished Zed. This is the first Zed where we’ve powder coated this much metal work.

Wide angle lense
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Just need to give everything a dust down and wipe off the finger prints.

Next update will be the test drive.
 

Mnbrennan

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Loverly job chaps. Can't wait to get the coupe done ;)
 
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Rha

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Yeh!!!!!! don’t let it go with dirty finger marks under the car, what ever would the MOT tester think. Would love to turn up at MOT station with this Z.

Just gonna check the coupe bonnet for dirty finger prints from last weeks MOT, there better not be any.:bag:
(somebody tell that crew it’s not nuclear fusion they’re working on)=))

Roy.:thumbsup:
 

Lee

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So finally after nearly 3 weeks the Bilsteins arrive. So flying solo today I got them fitted in the freezing cold, think it’s time to get the heaters outs.

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the most used bit of kit in my garage
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Old shocks are BMW original.
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There was also a last minute decision by Dom to change out the roll bar bushes for some Powerflex. So while I was on each corner I swapped them over.
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So finally it’s all looking really nice.
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Finally ready for test drive tomorrow.
 

pgunter

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One amazing Z3 and just goes to show, lack of use can be just as bad on bushes etc. The level gets upped on every Zed that goes through the shed. I would love to see the MOT inspectors face when he goes under that one...
 
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t-tony

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Top job Lee, and I agree about the temps dropping. Had to resort to a hoodie out in my shed last week and also been checking the Calor bottles ready for when it’s too cold. Finished servicing my mate‘s Fabia last Monday evening just gone 9.00 pm and it was a tad fresh.

Tony.
 
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