Day 5 - Subframe reassembly!
A full compliment of peeps in today including
@pgunter,
@Rally and
@mwpe! There was so much going on it's hard to keep a track, this has been a full on build and I've enjoyed every minute so far. Hoping for wheels down after a rare Sunday session tomorrow.
More reassembly pics, starting off with putting the hubs, brake shields and shoes.
These are the original brake shields blasted and powder coated, look almost brand new.
Hubs refitted along with the brake shoes. Kicking myself for not ordering a new set of brake furniture, but these are all hidden behind the mahoosive rear discs. They were all checked for function and then refitted, I don't use the handbrake much anyway - I'm old school leave it in gear when parked.
Top adjuster
Bottom handbrake cable pull mechanism
Test fitting the disc to check the shoes are mostly where we need them, will be set correctly when on the car. Ooooh, those discs
While the diff was on the bench, filled it with Castrol TRANSMAX Limited Slip LL 75W-140 Fully Synthetic Hypoid Gear Oil, and half a bottle of Red Line Limited-Slip Differential Friction Modifier (instructions as per bottle). Just levelled the diff on the bench, took out the filler plug and poured the oil in till it started to overfill. The FM was added in to the oil bottle part way through.
Next to the subframe reassembly. We had some figuring out to do with the Powerflex bushes, the instructions not 100% it's mainly a bit of common sense along with the photos supplied.
This is the diff bolted in to the subframe, you can't see the bushes from this picture but she's in and torqued down. We did have to unbolt it and retorque it later as some the camber arm bolt on one side can't be inserted unless you move the diff over slightly. We all stood and took a minute at this point, this looks soooo good...
Front Powerflex bush fitted as per their instructions. Washer, washer, then crush washer.
Then we drop it off the bench and start building everything back up again. This is part way through, upper wishbones & camber arms holding the trailing arms in place waiting to attach the half shafts to the diff and fit the anti roll bar.
The anti roll bar fitted, bolts to the back of the subframe unlike the Z3 where it attaches to the bottom of the car.
Fully reassembled ready to be offered up to the car.
We tried something different this time and utilised the gearbox jack which worked perfectly - so much easier than balancing it on a standard trolley jack.
....and she's back in and bolted in place.
Left Lee to get everything all checked over, tightened and torqued to specification where required while I got on with rebuilding the calipers. Started off with cleaning them to remove all the grit blast remains with the help of the air compressor. Once I was happy with them it was out with the Bigg Red seal kits.
Calipers now dry after a nice coating of black Hammerite.
Front caliper seals and piston refitted. We inspected the pistons and they are spot on, just a bit of corrosion on the outside when it touches the pads.
Rear caliper seals are a bit more of pain to refit as they cling to the outside, but we got there. The rear pistons have slightly worse corrosion but only on the face which touches the pads.
New brake bleed nipples fitted, and caliper slides suitably packed with silicon grease.
The discs are fitted ready for the calipers and braided lines tomorrow. The hubs have had a light spray of clear laquer to seal them and make them easier to clean in the future (thanks to Rally for the tip!).
We've almost run out of parts to fit, just a set of pads and braided brake & clutch lines left in the boot.
Great rebuild.