#ZedShed Family Owned 2.8 build (Subframe & Gearbox)

[Lee]

So next in the shed is Dom’s neighbour who has a family owned from birth 2.8, she’s been garage all her life and underneath is in totally stock form. Everything’s a bit wobbly and slack.

This Zed is going to have ‘Lock stock the lot’ including the gearbox shift pins, modernising the brakes along with other small bits.

So tonight we moved Andy’s Bella out into the cold, under a cover while we work on @JamesB Zed. We got her on stands so we can hit the ground running tomorrow morning.

even gave the floor a Hoover

looking totally stock

She’s had a nice interior upgrade during her life

common boot water leak

Stay tuned to see her subframe.

 

[TaffDaddy]

Looks very tidy

 

[RickyBobby]

Oh no don't think I can follow another one of these and resist the temptation to book mine in - think it's great what you're doing

 

[Lee]

Oh no don't think I can follow another one of these and resist the temptation to book mine in - think it's great what you're doing

Slide into my PM’s and we can talk

 

[andyglym]

Extended Tannin Red leather, it's the only way

 

[Lee]

So today we thought we would get the bulk of the hardware off so on Monday we can strip it down ready for coating. It’s nice laying under this car and seeing nothing has been molested, it’s all standard and clean. Every nut n bolt came off without fighting.

The exhaust came off with ease. We also noticed a flange part way down the exhaust, we’ll cut these bolts off later and fit some new ones.

I think we have a record for worn bushes. As most of you know these should be sitting up at least 10mm off the plate, these bushes have been resting on the plate for some time, you can even seen the tears in the rubber.

we’ve never seen a bush wear away the paint from impacts.

this is how the bush should sit.

Also while under the car I removed the prop and various brackets ready for the gearbox to be dropped.

Within an hour we were ready to drop the subframe. Only light surface corrosion in places, this will clean up and get sealed in.

Brake lines past it, this will be remade and the rubber part swapped out for braided.

fuel tank strap done a good 21 years of service.

The pile of hardware already mounting for coating.

So under two hours and the subframe was on the floor.

3.15 LSD sticker

underside looking good for 21 years.

next steps include cleaning the underside and sealing it in. Stripping and delivering items off to the coaters. Dropping the gearbox and fitting new shift pins. Still plenty to do.

stay tuned

 

[Lee]

Today was a strip down kinda day. First up was stripping down the rear beam and arms ready for coating.

Old bushes out made easy using the 12 Ton press

Next we started stripping the arms. Getting this intimate with everything we could start to see various things had been removed in the past, I’m pretty sure BMW don’t copper slip everything.

both arms stripped

one arm does give me a slight concern, there’s so much corrosion in the V I’m hoping after grit blasting it’s all still intact, all felt solid with a screwdriver.

We also noticed the offside wheel bearing had been changed in the past. Blue dust cover is original and red is aftermarket the dust cover was also a bit mangled on install. We laid it next to the new bearing also a red dust cover FAG unit.

Next I moved up to the front to remove various bits for coating, while I was there it was worth checking all the components, it was clear everything was past it, although aesthetically everything looked ok I could rotate the ball joints by hand and the tie rod end gators were cracked so I took the lot off.

Also the drop links

cracked tie rod gators

The fun bit stripping the whole arch out.

rack currently exposed waiting for new bits.

like with the rear we found the shocks to be in great condition. It’s clear they had been changed in the last few years. Gave one of them a quick wipe down.

While laying under the engine I could see some oil marks front and rear, they looked like they were drying instead of being a constant leak. The front leak appeared to be an old rocker gasket and the rear leak goes high, I’ll get a better look when I drop the gearbox.

Moving back onto the rear. We started de rusting the diff. Also come across the R stamp again, we’re pretty happy this means it’s been fitted with an LSD unit. also the rust we got off was crazy.

The rust..

Reach my photo limit. See next post.

 

[Lee]

So the bench at the moment is a mass of metal all ready for stripping and painting.

Something else I did before coming in is having a good look over the Zed and see what’s different or what extras it has. First thing I noticed was a cruise control function. The second lower wire is cruise.

Another odd thing I noticed was this car looks like it was supposed to be fitted with aircon or maybe it did in the past, bracket is there and the pulley is there but no pump and no button in the interior.

Also being a very early 2.8 it’s using the E36 crank sensor setup, you can just see the teeth on the crank wheel where the sensor picks up it’s location, all other zeds (newer) have a sensor at the rear of the engine.
She’s an early girl.

That’s the extent of my nosyness today, might notice a few more things when I drop the gearbox tomorrow. So far so good.

 

[t-tony]

Seeing the state of those rear beam bushes makes me wonder how it passed at least the previous MOT.

Tony.

 

[Lee]

Seeing the state of those rear beam bushes makes me wonder how it passed at least the previous MOT.

Tony.

I've had this very conversation with my local MOT guy, head said they cant actually fail it because they're contained.

 

[t-tony]

If you put a small bar in between the beam and the base plate and it moves they should. Any advisories on previous tests? Should be.

Borrowed from Testers manual.

You should only reject rubber or synthetic bushes when you can see serious deterioration of the bonding or flexible material.

I think that covers the pictures you posted Lee. TBH, I think many testers are more concerned with the money making things like shocks, springs, brakes etc.

Tony.

 

[Lee]

If you put a small bar in between the beam and the base plate and it moves they should. Any advisories on previous tests? Should be.

Borrowed from Testers manual.

You should only reject rubber or synthetic bushes when you can see serious deterioration of the bonding or flexible material.

I think that covers the pictures you posted Lee. TBH, I think many testers are more concerned with the money making things like shocks, springs, brakes etc.

Tony.

Remember though you cant see the bush without removing the arch liner, Something that's going to get worse as the years go on.

 

[Lee]

Today we did lots of the little gritty jobs. First up we dropped the subframe off to the coaters, with it was a subframe for an E46 track car plus some table legs.

next we thought we would get the gearbox out

then remove the pressure plate and clutch disc leaving a rather tired 22 year old
flywheel.

Once the flywheel was out the way I could inspect where the oil leak was coming from.

Re main seal not the cause, following the oil up you can see the rocker cover gasket leaking.

Now the only part left on the car is the engine. Still need to under seal the seems and fit new tank straps.

next it was stripping down the front hubs and start cleaning the brake assembly’s.

front hubs really tested me, both ABS sensors were seized and one bolt snapped, made further complicated by drilling it out then the M6 tap snapped in the hole, that took me a good few hours to sort. Luckily all sorted now.

Callipers coming up like new

Brake parts all now painted and drying

next I looked at the gearbox again, the pivot arm and release bearing were very worn. replacements on the way.

Gearbox looking good, shift pins will be ready for collection tomorrow.

another quick little job was refreshing the bolts on the exhaust, quick hacksaw job allowed the exhaust to be split into two.

tomorrow we should be rebuilding the gearbox and fitting the new clutch and flywheel, also getting a new rocker gasket to stop the front and rear oil leaks.

 

[andyglym]

Full strip down appears to be the new normal, great job. Table legs

 

[Fender2004]

Great job Lee, I was interested in the the photo the cruise control as I'm getting the bits to install it on my car, but I'm not sure how the cruise control cable attaches, would you be able to get me a better photo? I have a 97 m52 engine but it looks similar to the one in your photo.
Cheers.
Alan

 

[Lee]

Great job Lee, I was interested in the the photo the cruise control as I'm getting the bits to install it on my car, but I'm not sure how the cruise control cable attaches, would you be able to get me a better photo? I have a 97 m52 engine but it looks similar to the one in your photo.
Cheers.
Alan

I’ll grab some more photos tomorrow.

 

[Fender2004]

Cheers very much appreciated I know that it is a difficult area to photograph.

 

[Zag2]

Loving reading all this, thanks for the detailed photos. I'm learning every day and can't wait to see what lays beneath my own Z3!

 

[Lee]

Continuing on the lots of small jobs theme, first job was the gearbox shift pins we’ve done so many of these now we’ve got the process nailed.

lots of parts compliments of BMW

first 3 caps

new insert, spring and pin. This is the same process for all three

All three old pins removed

3 shinny new caps

next was the more difficult pins, 5th and Reverse. Both these are tough to remove because they have started to grab the bore hence the leaning 5th gear.

old 5th gear pin next to the new one.

old reverse Pin next to the new one.

reverse fitted and new cap with clip in. 5th new sleeve fitted before dropping in the new pin and spring.

full house of old pins and sleeves.

fitted the new pivot arm, thrust bearing.

Just some fresh oil to add and the gearbox is ready to go.

Next I moved onto fitting the new flywheel and cleaning up the old oil from the leaking rocker gasket above.

all locked in place ready to rock n roll.

A quick a satisfying job always is the fuel tank straps. Old straps next to new straps.

also fitted a new linkage bush, this really tightens up the gear change feel.

Photo limit reached.

 

[Lee]

Next I had lots of small jobs to do on the diff. I decided to completely pull it apart and give everything the once over.

first up remove the old bush

old bush next to new bush

also the speed sensor plate had totally blown so it was a good time to remove it and fit a new seal with plate

Dropped the oil and pulled the LSD unit.

Pressed in the new bush and speed sensor plate fitted.

all looking clean inside.

Now back together all the faces cleaned and ready to be buttoned up.

All closed up with a fresh coat of hammered black.

we also noticed after cleaning the rear shocks some serious corrosion so we’ve ordered a pair. Both sides in the same place, odd.

it’s also worth noting the amount of oil that came out the gearbox, I managed to barely get 500ml of fluid, no visible leaks... strange.

Now we wait for powder coat.