Bognor Lean-to Project

[Mazza]

Not so warm today… so had a few things around the house to do ….. but did go into the garage for about 3/4 hour…..

I think I will use the later diff as its done less miles. So next week will drop the rear axle. ( again )
I did have a look to see if the diff could be removed on its own … and it looks like it could be done… but putting one back would be a problem as I couldn’t get a torque wrench on two of the bolts…. And I will also have a trailing arm to put back …..so easier to drop it all, assemble / torque on the floor with easy access and lift it all back up again.

Diff bush not that brilliant….so off with the cover plate….

Cut the rubber out with a fret saw…

………..and using a file and dremel …

dont like cutting with a hack saw as too easy to cut into the casting. By filing and using a dremel…. It weakens a wider area and then just a careful tap using a screwdriver and a small hammer and the last part breaks

Once its snapped then its easy to knock it out of the casting.

What I wiil do is take the cover off the other one ( after draining the diff) and swap them over as there is a new bush on the other cover. And also reuse the oil as its new.

so the only cost will be a new gasket

 

[Mint]

Not so warm today… so had a few things around the house to do ….. but did go into the garage for about 3/4 hour…..

I think I will use the later diff as its done less miles. So next week will drop the rear axle. ( again )
I did have a look to see if the diff could be removed on its own … and it looks like it could be done… but putting one back would be a problem as I couldn’t get a torque wrench on two of the bolts…. And I will also have a trailing arm to put back …..so easier to drop it all, assemble / torque on the floor with easy access and lift it all back up again.

Diff bush not that brilliant….so off with the cover plate….
View attachment 267323

Cut the rubber out with a fret saw…

………..and using a file and dremel …

View attachment 267325

dont like cutting with a hack saw as too easy to cut into the casting. By filing and using a dremel…. It weakens a wider area and then just a careful tap using a screwdriver and a small hammer and the last part breaks
View attachment 267327
Once its snapped then its easy to knock it out of the casting.

What I wiil do is take the cover off the other one ( after draining the diff) and swap them over as there is a new bush on the other cover. And also reuse the oil as its new.

so the only cost will be a new gasket

You're looking for work now Malc

 

[Mazza]

I’m not Honest…. It keeps finding me

 

[Mazza]

Got my finger out today....and got on with some work....

First Port of Call.....the local Stealer in Rustington, to collect 2 diff gaskets and two diff plug washers.

Back about 10am....so on with the car.....
.........You put the rear beam in, the rear beam out,
In Out , In Out
And change the bits about
You do a lot of swearing and you bang your head
Oh why did I buy this Zed.......

Enough of that........ but I bet most of you sang it in your head

Because one arm has already been removed the weight of the beam would be off centre so removed the other arm first.
Having done this recently fairly easy to do...just had to stop the hub turning to unbolt the driveshaft..

But soon out

Then realised I would have to drop the whole exhaust.... what a pain!!!!!
The front end was still sitting on its wheels, so used two trolley jacks to take it up bit by bit on each side to get some axle stands installed

Then took off the offside wheel to get more access but what a game getting all the nuts and bolts off the front flanges.
Then disconnected the after cat sensors, pulled the rubber mount off the beam support....managed to get one of the rear box mounts off but the other one was a nightmare to cut the bloody thing off.....( will need to give Andy a call )
Used some axle stands to support it until I could get it on the floor.....bloody heavy!!!!

With that off...undid the screws of doom...... or the ones I used as replacements.....came off so easily

Then the two beam bolts and the diff support bolt
And with a bit of jigging it... it was on the floor and 4 bolts later dismantled

So back to square one !!!! And where I was months ago......

So now a visit on saturday to Basingstoke and hopefully get the arm stripped and off to get powder coated.
Will also see about the rest of the stuff while I’m at it ....useful spares !!
Then just put it all back in the garage....

I can start to rebuild the beam assembly with the new diff and nearside arm in readiness for getting the offside one back.
So that will give me a bit to do in the meanwhile.

 

[t-tony]

What did you do after lunch Malc . . . . . . ?

Tony.

 

[colb]

I would change those alloy diff plug washers for some decent copper ones, the alloy ones I took off my Z4 were like lace from corrossion, surprised they held the oil at bay.

 

[Mazza]

Well an early run to Zedshed HQ today via breakfast van……
Took the damaged arm and the replacement one for stripping down
… didn’t take the beam or the other arm ( save those for another day)

Lots going on today and was really thankful that my jobs could be fitted in.
The damaged arm was a nightmare and took over an hour before the nut finally came off.
A combination of Gaz , Lee, Trev and me and a nugger gun finally got it off.
Then I got tuition from Gaz on the extractors and the hub and backplate were soon removed.

As we went about removing the bearing from the damaged one …. Only then did I mention that it was all scrap…. So we didn’t really need to remove it

Then on to the replacement …. Nugger gun and the nut was off in seconds…. So then I was left to work out how to set up the extractors… ( and I even remembered to take out the big bearing circlip)
Gaz was impressed that I actually set it up correctly…. But he didn’t know that Trev had checked it and made some adjustments
Anyway replacement arm duly stripped of the hub , bearing and backplate and now ready to go to powder coating with other parts that Lee has.

That will come back looking pristine… then rebuild with a new bearing and bushes and finally get the beam assembly sorted.

Parts for me to clean in the meantime

And one bent trailing arm in the metal waste bin…. Where it belongs

A big thank you to Gaz and Lee for helping me with this, and hopefully it has kickstarted the rebuild .

I left as they were just about to install a 3” Mega exhaust onto Gaz’s mini, having already done a similar job on Lee’s Z4.

Didn’t see a lot of Paul and Hollie today as they were busy on other things, and for once I was actually doing something…
it was also nice to see Mike and Martin today.

So a good day for me … and got a few things to do before off fishing in Cornwall next week.
There may be drinking involved as well

 

[Mazza]

Not a lot done in the last couple of days as I have been sorting out stuff for my trip to Cornwall….

But I did need to move the bonnet as couldn’t get to the parts washer….
Its been under the sheet since I picked it up

but now in its new home…..
the spare bedroom !!!!

Even had to take the tele off the wall to make room…. ( Tricia would have killed me )

But its out of the way and safe there.

Swapped over the covers for the two diffs, which are both LSD… so may sell the spare at some point.
Just need to spray the casing now as its been cleaned and treated.

I thought one was LHD …. But it was upside down

And all ready for the replacement arm
as the last part arrived this morning
Lockwasher and Nut from BMW, Meyle bushes from Motormec, and Febi Bearing from Automotion Factors.

I did clean all the parts and will have a few spares for later , but still need to remove the outer bearing race from the hubs

Only thing to do now is to hide the keys to the 1.9 to stop the kids and grandchildren using it while I am away

 

[Mazza]

Sitting in St Austell waiting to go to brekkie

Great time down here and met up for a beer with Garry (@Jack Ratt) Always nice to meet another forum member and put a face to a name.

As for the fishing…..
Ist afternoon at Mevagissy one mackerel…
My mate also had one…. But a sesl nicked most of if as he reeled it in
Day 2. Gorram. Loads of mackerel and one small conger eel
My mate had just mackerel
Day 3 out on a boat…. 8 whiting and 5 Congers heaviest 30lbs my mate had 12 whiting and 11 congers ( but not as heavy as mine )
Day 4 shark boat…….2 blue sharks 50lb and 90lb my mate had one of 60lbs

other than the whiting caught on the boat, everything else was return to the sea in full working order

Now a 4 hour drive back later and get back working on the car

 

[Jack Ratt]

Sitting in St Austell waiting to go to brekkie

Great time down here and met up for a beer with Garry (@Jack Ratt) Always nice to meet another forum member and put a face to a name.

As for the fishing…..
Ist afternoon at Mevagissy one mackerel…
My mate also had one…. But a sesl nicked most of if as he reeled it in
Day 2. Gorram. Loads of mackerel and one small conger eel
My mate had just mackerel
Day 3 out on a boat…. 8 whiting and 5 Congers heaviest 30lbs my mate had 12 whiting and 11 congers ( but not as heavy as mine )
Day 4 shark boat…….2 blue sharks 50lb and 90lb my mate had one of 60lbs

other than the whiting caught on the boat, everything else was return to the sea in full working order

Now a 4 hour drive back later and get back working on the car

It was great to me you too Malc. I'm glad the fishing trip got better for you after the first 2 days

 

[Mazza]

Up to Zedshed HQ today, taking the spare arm and beam to strip down.

First job was to get the nut off and knock the the shaft out. Nugger gun and a drift and got them off all by myself ( something about a giant leap for mankind springs to mind)

Other than at one point I forgot to remove the bearing circlip , managed to get all the tooling to extract the hub, then the bearing round the right way. Two man job though to hold one nut with a spanner and wind the other end with a socket ….. my expertise turns out to be holding the spanner and acting as ballast to stop the arm moving while Trev (on the Hub), and Gaz (on the bearing), wound the parts off.
( I know my place)

The whole thing took about 20 minutes to strip down which was pretty good for me .

Another arm ready to go for blasting and painting.

Lots going on today…
Paul And Trev were working on Richards Z3 sorting out a fault code. Smog Filter removed and bits then blanked off which cured the problem.

Lee, Rob and Gaz were replacing the gear lever in Lee’s Z4M

I should have got a picture of new gear stick but forgot ( nice bit of kit though)

Then later on Hollie and Gaz replaced the rear springs , Discs and Pads on an Astra.

A while before doing this though Hollie helped me …..(actually she did all the work ) ….on removing the bushes from two beams ( mine was one of them )
I just held them while the ends were heated up and then the bushes pushed out on the press.

Which then were put on the pile of stuff to be refurbished

Another fun day ….. and breakfast too !!!

 

[Lee]

Was another good day mate. So much got done and lots of tea consumed

Thanks for coming down and looking after me

 

[Mazza]

Just a addition to earlier post....

Richards car had a fuel fault code, but the problem was traced to the vacuum lines on the air pump.

Item 4 had degraded, as had Item 7, so pump item 1 removed, along with items , 2, 3.4.6 and 7.
Pump blanked off with a plate ( ref @t-tony ) and the vaccum spigot ( where item 7 attaches on the manifold was blanked off by item 14 below.

Another blanking plug (Item 19) had also degraded and needed to be replaced.

But after fault code reader reset, and a drive , no faults found....

 

[rmoconnor41]

Just a addition to earlier post....

Richards car had a fuel fault code, but the problem was traced to the vacuum lines on the air pump.

View attachment 269775

Item 4 had degraded, as had Item 7, so pump item 1 removed, along with items , 2, 3.4.6 and 7.
Pump blanked off with a plate ( ref @t-tony ) and the vaccum spigot ( where item 7 attaches on the manifold was blanked off by item 14 below.
View attachment 269777

Another blanking plug (Item 19) had also degraded and needed to be replaced.

But after fault code reader reset, and a drive , no faults found....

Lots of scraped knuckles. A big thank you to all involved

 

[Mazzal]

With all this work going on am thinking to myself about getting a number of Zeds - afternoon nap - zzzzzzzzzzzzz - see you at the pub later for a rock star concert

 

[Mazzal]

 

[Mazza]

Back in the garage this afternoon….
Sorted out the diff, fitted the new gasket and filled with oil…. Ready to assemble now

which means I have the other one to assemble, shotblast and spray ready to sell.
along with the two drive shafts and a n/s arm and beam ( when they have been refurbished)

Then the other little job was to cut the outer bearing shell off three hubs….. so out with Derek the Dremel…. And a cutting blade….

It was lucky to have two spares as I went a little deep on the first one …. But better on the other two.

I am reliably informed that the small cut wont have any effect on the hub. Just need to make sure no sharp edges that would hinder it being re assembled at some point.

so ….two spare hubs to clean and add to the ‘for sale’ pile

A word of warning …. Dremel Cutting Discs can fly off…. As one whizzed past my ear

 

[spurs fan in a coupe]

The Z3 van Gogh

 

[Mazza]

After a trip to Zedshed HQ yesterday…. I now have a my refurbished drivers side trailing arm after some work was carried out by the guys
First job.
Remove a broken bolt ( should have done it before the powder coating )
But careful drilling and tapping and success

Then put the two bushes in… greased the arm and checked I had them round the right way, and was allowed to use the Precision Insertion Tool on my own

And the Precision Insertion tool

Really easy to push them in and then use a socket for clearance for the last bit.

Then the Bearing was added….

I did ask Paul if he was putting it in correctly…..when I zoomed in, I got my answer…..

It needed 3 people, so Trev gave a hand and also put the circlip in , making sure it was seated correctly

Then Back plate went on and the Hub inserted

but not before a slight problem ( as it was my fault …there are no pictures or what happened ) , but issue overcome and sorted… nice to have people who really know these cars

And now one Arm ready for me to carry on

The powder coat finish is amazing ….

I did do one thing this morning….just 4 bolts!!
Beam to Diff…..

Going to build up brakes etc on the arm, then
fit the two arms to the beam, torque it all and then just lift it back into the car …. …..Simples!!

 

[Mazza]

So early start this morning....
First thing was to get all the bits together....and found the brake cable has got surface rust on one end....so a quick clean with a wire brush, undercoat, and satin black to finish.

After it had dried, onwards with reassembling the rest of the arm
And in no time at all the arm was ready ......

All good you would think.....no, because at this point I found the new brake cable .......the one I painted and fitted was the old one I took off the donor unit

what a plonker I am

Anyway about 20mins later, I had stripped it all down, fitted the new cable, and rebuilt it.....but it had to be done


The next phase was putting both arms back on the beam, and connecting the axles ....you have seen this all before so no pics this time.....then final job was to torque all the bolts .....
Et Voila.......

Tried to wheel the lot under the car but it wasn’t as high off the ground as it was originally........so had to lift the car a bit higher on the axle stands. The axle assembly then glided into position....but not before I trapped my finger trying to centralise it on the wheels.......ouch !!!!

So more or less in place ready to be lifted up....but not today....off to footy now

Its a balacing act trying to get the propshaft to mesh in, the two beam bushes to line up and the diff bush to locate.....
But with 4 jacks, and having done it numerous time before, it should not take too long to get it in tomorrow.