Rear end maintenance + other bits

[Davyhoogy]

Copying @Antm72 and having a bit of a do up of the rear end of the car, but nowhere near to the same extent.
This has came about because of the MOT fail which was rear main brake pipes corroded.
I've got a list of things I want to do so thought this was the time to do it all. It will mean the car will be without an MOT until the work is all done.

- replace all brake pipes
- replace diff bush with powerflex
- replace beam bushes with oem equivalent
- clean up / paint the trailing arms and rear beam
- thicker spring pads
- replace full handbrake system
- replace rear heat shield
- new sills
- New front wings
- paint front bumper

I made a bit of a start tonight but only had a couple hours.

Brady helping as always...

The rusty brake pipes in question

Tank straps aren't completely rotten but they might have to go on the list if they don't clean up! Any advice on these appreciated.

The diff bush has seen better days yet wasn't raised on the MOT.

Step 1 and already an issue, handbrake cables, I can' get them undone, these are so tight!! I may just cut them from the other end and pull them through?

Heatshield has rotten where the washers go over so that will need replacing. Why didn't I keep the ones from the donor car I had

The rear carrier might just be left off completely, haven't decided yet. It'll need a new spare.

This is where we are so far. Probably not have time tomorrow but Saturday morning if I can sort the handbrake cables out then I should have the beam out.

RIGHT. Some worrying images coming up. Under the rear most heatshield, where the back box is, this has been revealed!

What do we think? Simple hammer it shut and weld it?

Also this is the condition of the diff mount from the underside. The infamous diff mount repairs have been carried out by a previous owner. But doesn't look amazing. I will cean it up and get a better look.

@Antm72 what's the best way to disconnect the propshaft from the diff?

 

[5harp3y]

Handbrake cables shouldn't be too tight at that end just make sure the handle is down

For the prop just undo the 4 nuts with the handbrake on and then when you lower the beam the prop will fall away from the diff

Tank straps look OK, I'd just clean them up and paint them

 

[Antm72]

I used another spanner to lock the prop against the carrier as i had already disconnected my handbrake if you havent use it to lock the diff
I had a few rotted through points i brought i order some 35 mm washes and it resolved the issues.

 

[Antm72]

Only one tank strap is availible the short one.I have payed for the other one but its not come and ywo dead lines have noth passed will get a refund as not sure it will arrive . I had one strap new the other blasted and powder coated.

 

[Mint]

Dave sorry if I'm teaching you to suck eggs but there is a locking nut on the handbrake cables.

 

[Davyhoogy]

Dave sorry if I'm teaching you to suck eggs but there is a locking nut on the handbrake cables.

The b**tards won't budge!

 

[Mint]

The b**tards won't budge!

They look pretty new, perhaps a spot of WD40?

 

[How 29]

Hope it doesn't rain on you now you have got it stripped that far. Would never get anything like that done outside in Rochdale.

 

[Jjim]

Is that crack on the sill or boot?

 

[Bozzy]

Good on ya for tackling these jobs outside mate, fingers crossed the weather stays dry for you.

 

[Sean d]

f*** me Dave, if you are struggling with the hand brake nuts you are in for a big surprise when you get underneath , you will need one of these

 

[Sean d]

Is that crack on the sill or boot?

The crack is on the rear cross member that the diff mounts too, its quite a common problem on the higher powered models due to the crap diff mount design

 

[Davyhoogy]

I think we are due a dry day today then rain all weekend, typical.
If I can get it out and in the garage by tonight I can still work on it

 

[roadvoyager1]

Mark up the prop shaft and diff flanges so it goes back on the same position. I have seen a few comments about the prop running out of balance if it is not put back the same. Don’t know if it is a real issue but it is easy to do and possibly avoids a problem.
Also loosen of the big nut that hold the rear beam on whilst the car is still on its wheels they are "rather" tight and the car needs to be stable when you start haulling on that long breaker bar.
The side brackets have locktight on the Allen bolts and you may need a bit of heat applying to get them out. Whatever you do don't strip the heads.

 

[Davyhoogy]

A neighbour has a Makita high powered impact gun which took the beam nuts straight off on the other car I did so I'll be using that again. I will remember to add heat to the brackets though just incase. They have all been coated in wd40 the last 2 daya

 

[Steve Medlock]

The b**tards won't budge!

A deep socket is useful for those. I think I had a ring spanner backwards on the adjuster nut and a deep socket on the lock nut.

 

[Davyhoogy]

Few more hours today and a spare pair of hands to help.
I had to remove the centre console to get to the nuts properly on the handbrake lever but got them in the end.

As usual that bracket under the main beam bushes was a bit tough to get off and scares the living hell out of you when
they bang and come loose.

Everything else came off with relative ease.

I now have the full axle in my garage so I can work on it tomorrow when it rains.
I have a stag tomorrow night so won't get as much done as I would like, also my brake pipe kit hasn't arrived yet.
The new handbrake shoes arrive but there isn't much difference to the old, even though they are dated 2007!
I'll be doing hours of rust removal tomorrow.

Would I be best to strip the whole thing apart and then it would be easier to clean/paint each section . I think it will but I have no idea how to. Make it up as I go along lol

 

[Antm72]

i stripped it down so it was as light as possible to put back.
You have to undo both swing arms and the diff mounts to seperate the beam this will help with bush removal.
The arms will then rotate 180° so you can clean top and bottom. I painted the tops out of the car and waited till it was hung back in the car and painted the rest before rebuilding the brakes and , brake pipes that fit on the arms.

 

[Mint]

Good effort Dave, keep going. I take it Sunday will be a rest day

 

[Davyhoogy]

Good effort Dave, keep going. I take it Sunday will be a rest day

Sunday midday Kate is back from the hen party in Dublin. So Sunday 8-12 Will be 'tidy the house and pretend nothing ever happened'