#ZedShed Millers Z3M overhaul (Gearbox & Subframe)
- Thread starter Lee
- Start date
They're not being reused as we're fitting KW coil overs but the front springs are M specific and worth keeping if Miller ever wants to return his zed back to factory, they actually don't appear to have much corrosion so will come up like new.
Being recycled I shouldn't wonder. Makes sense.
Tony.
Tony.
Yeah exactly that, we also have a HnR roll bar kit to fit. Still worth powder coating the old bars. All these parts will become harder and harder to source as the years go on.
In that case I could apply for a green number plate with all the recycling my old shed has done
Mine's 18 this year so I'll be starting soon ................................
Tony.
Tony.
First load of powder coated items collected today, while I was there I dropped off the plenum and engine covers today really looking forward to see how they turn out.
Couple of bits to remove off the plenum before drop off.
I couldn’t help myself so unwrapped everything for a sneaky peek. Laid out the arms and beam.
the little bits & bobs came up well considering
Springs look really good. Saved from the bin.
roll bars and brace also came up well.
it’s worth noting the grit blasting process killed the bearings, they’re all full of grit so they will have to be replaced. I dropped the arms off to a heavy engineering place this morning because our new bearing tool is on its way.
Progress
Couple of bits to remove off the plenum before drop off.
I couldn’t help myself so unwrapped everything for a sneaky peek. Laid out the arms and beam.
Springs look really good. Saved from the bin.
roll bars and brace also came up well.
it’s worth noting the grit blasting process killed the bearings, they’re all full of grit so they will have to be replaced. I dropped the arms off to a heavy engineering place this morning because our new bearing tool is on its way.
Progress
Was the bearing tool under warranty Lee?
Tony.
Tony.
It was an eBay job and it’s over a year old easier to buy a new one.
Today’s jobs went as planned. I collected the rear swing arms minus the bushes, the guys said it was just that one side and took a 15ton press to remove the other side was fine.
I cracked on removing the rear brake lines. They literally crumbled soon as you touched them, we got them in good time. Luckily with the 3 way block at the rear it makes replacing them far easier on the M.
the front didn’t go so well. Soon as I started trying to get the fitting apart brake fluid started dripping from behind the arch liner. I’ll have to replace these hard lines from the abs pump up to the bracket. Glad these failed here and not driving out somewhere.
And with the manifold/plenum away for coating it makes access perfect for running new brake lines.
Tomorrow it’s time to remove the gearbox.
I cracked on removing the rear brake lines. They literally crumbled soon as you touched them, we got them in good time. Luckily with the 3 way block at the rear it makes replacing them far easier on the M.
the front didn’t go so well. Soon as I started trying to get the fitting apart brake fluid started dripping from behind the arch liner. I’ll have to replace these hard lines from the abs pump up to the bracket. Glad these failed here and not driving out somewhere.
And with the manifold/plenum away for coating it makes access perfect for running new brake lines.
Tomorrow it’s time to remove the gearbox.
Today was a day that felt like I was making progress. I’ve had too many days of constantly finding more problems. So today we nice to start putting things back together.
First things we built were the arms. New FAG wheel bearings with new dust shields and new handbrake mechanism. I had a chuckle when I removed the old mech because Miller has history with handbrakes failing, this one was just about to do the same thing.
Dust shield
new mech
then the next arm. Rinse repeat (bung missing in this photo)
we then also fitted the 4 new swing arm bushes. No expense spared. Lemforder parts, very easy to fit with some grease and a vice.
then it was time for the new beam bushes.
and laid out again looking a bit more complete.
While we waited for the kettle to boil I quickly made up the new rear brake lines. Used the old ones as a template, they look spot on.
that’s the rear ready to rock. Only if the front was going to be that easy.
Next we did a bit of painting. The brake parts now starting to look like new again.
Now for the grand event, the gearbox removal. We’ve got this down to an art now. 45mins if all the bolts come out without protesting.
Always remove the vicious fan because the engine rocks about a bit, this would damage the rad with the fan on.
It was clear this was the original clutch. Not looking to bad to be fair.
Least the oil leak looks low down, possible sump plate. Also my bottle jack on the aircon pulley in the background keeping the engine level, don’t want to damage the mounts.
Everything laid out.
Not too many heat marks.
clutch disc just starting to go.
She’s looking very empty now. That’s everything off now it’s clean, paint and rebuild. Anyone know where all these bolts go??
next week should be full steam ahead.
First things we built were the arms. New FAG wheel bearings with new dust shields and new handbrake mechanism. I had a chuckle when I removed the old mech because Miller has history with handbrakes failing, this one was just about to do the same thing.
Dust shield
new mech
then the next arm. Rinse repeat (bung missing in this photo)
we then also fitted the 4 new swing arm bushes. No expense spared. Lemforder parts, very easy to fit with some grease and a vice.
then it was time for the new beam bushes.
and laid out again looking a bit more complete.
While we waited for the kettle to boil I quickly made up the new rear brake lines. Used the old ones as a template, they look spot on.
that’s the rear ready to rock. Only if the front was going to be that easy.
Next we did a bit of painting. The brake parts now starting to look like new again.
Always remove the vicious fan because the engine rocks about a bit, this would damage the rad with the fan on.
It was clear this was the original clutch. Not looking to bad to be fair.
Everything laid out.
Not too many heat marks.
clutch disc just starting to go.
She’s looking very empty now. That’s everything off now it’s clean, paint and rebuild. Anyone know where all these bolts go??
next week should be full steam ahead.
Strange that the clutch was not to bad as I seemed to be able to make it slip with a couple of let’s say “spirited” accelerationsToday was a day that felt like I was making progress. I’ve had too many days of constantly finding more problems. So today we nice to start putting things back together.
First things we built were the arms. New FAG wheel bearings with new dust shields and new handbrake mechanism. I had a chuckle when I removed the old mech because Miller has history with handbrakes failing, this one was just about to do the same thing.
View attachment 175205
Dust shield
View attachment 175207
new mech
View attachment 175209
then the next arm. Rinse repeat (bung missing in this photo)
View attachment 175211
View attachment 175215
we then also fitted the 4 new swing arm bushes. No expense spared. Lemforder parts, very easy to fit with some grease and a vice.
View attachment 175213
then it was time for the new beam bushes.
View attachment 175217
and laid out again looking a bit more complete.
View attachment 175223
While we waited for the kettle to boil I quickly made up the new rear brake lines. Used the old ones as a template, they look spot on.
View attachment 175227
that’s the rear ready to rock. Only if the front was going to be that easy.
View attachment 175225
Next we did a bit of painting. The brake parts now starting to look like new again.
View attachment 175221
View attachment 175219Now for the grand event, the gearbox removal. We’ve got this down to an art now. 45mins if all the bolts come out without protesting.
Always remove the vicious fan because the engine rocks about a bit, this would damage the rad with the fan on.
View attachment 175229
It was clear this was the original clutch. Not looking to bad to be fair.
View attachment 175231Least the oil leak looks low down, possible sump plate. Also my bottle jack on the aircon pulley in the background keeping the engine level, don’t want to damage the mounts.
View attachment 175233
Everything laid out.
View attachment 175235
Not too many heat marks.
View attachment 175239
clutch disc just starting to go.
View attachment 175237
She’s looking very empty now. That’s everything off now it’s clean, paint and rebuild. Anyone know where all these bolts go??
View attachment 175241
next week should be full steam ahead.
.i always follow the rebuild threads but it adds a totally new dimension to it when it’s your own.the funny thing is it will probably cost more than I paid for the car...gulp 
That is an amazing teardown / write up. I'm really looking forward to the next exciting episode...
Really cracking work, Thanks!
Really cracking work, Thanks!
It’s the same gearbox, I can only assume the bolt pattern allows the gearbox to sit at a slightly different angle.
just compared two photos at the same angle. The 3.2 head is wider than the 2.8. Must allow the extra clearance.
Fascinating thread!