#ZedShed Swamper Z3M Subframe & Gearbox

Lee

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British Zeds
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Finally now back playing with zeds again we’re in for a treat. Just before Christmas @swamper dropped in his Zed for some love. He’s been watching my builds one by one over social media and really wanted his M to get the same treatment.

First up was assuming the Zed position. This is the best way to sit the zeds so the subframe can be dropped at the rear and the gearbox in the middle.
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Once she’s in the air get the wheels off and take stock of the current condition of everything. The word Crispy keeps jumping out at me.

Rear
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Front
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She’s not that bad at all for 22 years old. First things I noticed were odd front callipers. Swamper tells me he has a new set to build at home. One calliper was lacking the embossed M logo.
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Next was checking the exhaust bolts. I love the M setup everything comes off in 3 sections. Bolts didn’t put up a fight at all, we will replace all these bolts.
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Whilst rolling around under the car I did notice a lovely impact on the Cat. Nothing a quick hammer couldn’t tidy up.
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fuel tank straps looking flakey.
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And finally removing the arch liners to reveal the very tired beam bushes. Sat on the plates.
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Now with a plan of attack it was full steam ahead gutting the underside. This was a good hour nothing really gave us any trouble. Old crispy springs. These are HnR lowering springs. Because Swamper plans to fit KW3 coilovers in future we’ll re powder coat these to get a couple more years out of them
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Roll bar caps and drop links. We’ll replace the roll bar bushes with Superpro poly, best value for money at the moment.

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New Calender making an appearance. Had to make my own this year.
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Reached the 20 photo limit. Part 2 coming
 
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Lee

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British Zeds
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Z3 Roadie 2.8TU
So within 2 hours we were ready to drop the subframe. Last bits to move out the way being the subframe plates. These will also go away for coating.
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Subframe came down with no issues. With the M model there’s actually less work involved over a non M model, no spare wheel to remove and no brake line systems to disturb. The brakes run above the subframes on the M models, such a great idea.
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the subtle differences with the M’s.
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the underside looking clean, some very light surface rust.
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nothing gets past our eyes with these zeds. Straight away we spotted some extra welding done on the diff hanger and frame across the boot. Shame they didn’t remove the Sealent before welding because they burnt it.
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Rear brake 3 way valve.
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Bench actually looking tidy.
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Tomorrow will be a complete tear down to component form ready for powder coat.
 
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Lee

Zorg Guru (V)
British Zeds
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Nice. Do you have videos on youtube?
This is something we’ve discussed a lot in the shed. Maybe something we might do if things ever return to normal. We’re normally a team of 4 but only running as 2 during this lockdown.
 

Lee

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British Zeds
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#ZedShed
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Z3 Roadie 2.8TU
Today was a mega busy day stripping everything down. It was also a little bit of a learning curve because we’ve never removed the bearings on an M before, turns out they’re just as simple, we had to do the hub removal slightly differently.

First up was stripping down each arm. Our plan was to get each arm down to just hub and bearing left and tackle both together.

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Leaving it looking like this.
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The only difference we had was where the hub sits flush against the beam, normally we clamp the bearing puller in that gap. So we had to tap the hub out manually at least 10mm in order to fit the puller. These next photos show the hub already removed and the bearing about to be pulled. Again all done with manual tools.
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leaving the arm bare like this. Look at the size of it. Huge over the non M arms.
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Thought this would make an interesting photo. I’ll make a separate sticky. Left to right: M hub, 6 Cyl hub and 4 Cyl hub. I also took a load of measurements.
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Now the arms are stripped next was the beam bushes. Olds ones next to a fresh new bush.
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then we removed the diff bush ready for its new replacement.
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be very careful not to catch the Ali hacksawing out the old ring.
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old bush next to new.
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that concludes the rear strip down. Next it was a few items up front. We needed the front roll bar and springs for powder coat.
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then disassembly in safety.
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of course it wouldn’t be a real strip down without one snapped bolt. One of the lower shock bolts refused to undo. Luckily this is becoming the norm and 20mins later a few drill bits and a M12x1.75 tap all was well again.
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so the hub had to come off to make things easier.
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hey presto.
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very satisfying.
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Everything laid out, being dropped off tomorrow at 10am.
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so as she stands there’s not much left on the car.
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Tomorrow is gearbox off and indent pins. :D
 

Lee

Zorg Guru (V)
British Zeds
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#ZedShed
Joined
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Messages
3,768
Location
Basingstoke
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Z3 Roadie 2.8TU
Only a little update while everything’s at the powder coaters. We pulled the gearbox today.

Gearbox removed showing the clutch assembly.
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Then clutch assembly removed.
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Everything on the bench.
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again another very tired clutch disc and flywheel showing signs of heat marks.
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Release bearing was very stiff to turn by hand. All these items here will be replaced.
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Diff also got a clean up.
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A boot full of goodies waiting to be fitted. Worth noting when I collected the parts from BMW today most of them are coming up the same price as my local Euro/GSF. I think going forward I’m going to start using them more.
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The under side of the Zed looking very empty.
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swamper

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British Zeds
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Bacup
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z3m
I'm gobsmacked....😳
Thanks for the update Lee 😉
 
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