Rear end maintenance + other bits

[t-tony]

Today was the big day. Rear end was going in. Got a few mates round and after a bit of carry on we got it in..... Yay!
However, diff bush and diff bracket were maybe 2mm out of alignment. Not to worry, managed to get it in so the welding was pretty much in the right place.
Everything fitted and connected but 1 last issue.
The inner sleeves of the beam bushes are still too long I think.View attachment 85786 View attachment 85785 I did cut about 10mm from them but I think they need more. @Sean d
I'm thinking if I take those brackets off and try and wiggle the inner sleeve down, I can use a cutting disc and trim another 3/4mm off.
Also are the brackets on the bottom the correct way? I think they are.

Then the last issue, rear beam is fitted in place and the drive shaft doesn't reach the input coupling on the diff...1 bolt is poking through but other 3 aren't. Am I missing something here cause I can't think?
View attachment 85787
I didn't get a pic of it all fitted I was too excited.

Very very happy man.

On the prop shaft Davy, is it possible that the sliding section of the shaft is seized due to being stood too long? I really can't see what else could "shorten" the shaft mate, if it is that some release oil and a knocking stick should sort it.

Tony.

 

[Davyhoogy]

On the prop shaft Davy, is it possible that the sliding section of the shaft is seized due to being stood too long? I really can't see what else could "shorten" the shaft mate, if it is that some release oil and a knocking stick should sort it.

Tony.

I was thinking it must be able to pull back and forth. I can't remember if it did, which part?

 

[Sean d]

I'm sure I asked ya and you said yours didn't come with a washer lol. So it's all got to come back out again

After seeing yours with washers I rang Duraflex and they posted a set out to me, he said washer at the top but yours alrady looks to have one

 

[Sean d]

Mine needed top washers as the post at the top was very narrow but yours looks ok as it comes to the edge of the bush

 

[t-tony]

I was thinking it must be able to pull back and forth. I can't remember if it did, which part?

Hi mate it slides at the centre bearing assembly going by this from Real Oem.

Hope this helps mate. I bet the splines are stuck.

Tony.

 

[Davyhoogy]

After seeing yours with washers I rang Duraflex and they posted a set out to me, he said washer at the top but yours alrady looks to have one

Ah right I see. I emailed them but didn't get a reply a while ago.
Do you have a pic of yours where you can see them at the correct height? I still need to trim a bit off the sleeve as the bracket on the bottom isn't high enough for the Allen bolts to go in

 

[Sean d]

Ah right I see. I emailed them but didn't get a reply a while ago.
Do you have a pic of yours where you can see them at the correct height? I still need to trim a bit off the sleeve as the bracket on the bottom isn't high enough for the Allen bolts to go in

I don't have a pic but really had to compress the bush to get the right height for the bracket to locate

 

[Davyhoogy]

Let me try my best here, bear with me lol.
@Sean d

Right so the mounting pins have a hex nut shape at the top of the pin...

In this pic the bush, as it is right now, has been pushed up as much as it will go and is sat flush with the top of the mount with no gap....

If I put that washer on the top, it would only go up to the hex bit and stop there, so there would be a gap where I drew that red line.

 

[Sean d]

Let me try my best here, bear with me lol.
@Sean d

Right so the mounting pins have a hex nut shape at the top of the pin...View attachment 85866


In this pic the bush, as it is right now, has been pushed up as much as it will go and is sat flush with the top of the mount with no gap....View attachment 85865

If I put that washer on the top, it would only go up to the hex bit and stop there, so there would be a gap where I drew that red line.

@t-tony what do you think

 

[Sean d]

It might be the camera angle but the locating bolt in the second pic looks a bit bent to one side

 

[Davyhoogy]

It might be the camera angle but the locating bolt in the second pic looks a bit bent to one side

It's a very zoomed in pic but it does a bit. It possibly was as my road is unlevel and lowering off the pins sometimes the frame twists as you probably experienced it can be a bit tricky. I've never noticed just by looking at it though.

 

[roadvoyager1]

Been 10 months since I did mine but as I recall the hex nut and washer should be tight against the chassis member. Yours has 15mm or so of plain shaft visible. Unfortunatrly didn't take any photos and relying on my memory so could be wrong.

 

[Davyhoogy]

So after some digging it appears the washer does go at the top, flush with that hex and that there will be a gap above.
Apparently ASC did kits with washers that packed this gap to prevent and further movement... see below

 

[Davyhoogy]

FINISHED. (Apart from a rear heat shield, some interior trim and a bit of paint).

First very gentle (mot-less) drive around the block, All seems ok. Didn't blow up or have z brake failure.

 

[the Nefyn cat]

Feels good, don't it. I remember how it felt getting mine back together after doing the back end. Just a matter of getting used to the new noises.

 

[Davyhoogy]

Feels good, don't it. I remember how it felt getting mine back together after doing the back end. Just a matter of getting used to the new noises.

Someone was cutting concrete in the next street, I was like "s**t is that my brakes binding"? Haha. Very on edge.
I can't wait to get on a motorway at 56mph and get some easy miles on it.

 

[the Nefyn cat]

All the new, stiffer bushes will make it sound different, more so with the roof up. That's why the stereo has a volume knob.

 

[Z3I]

That first drive after so much work! Talk about nerves! Well done.

 

[Sean d]

FINISHED. (Apart from a rear heat shield, some interior trim and a bit of paint).
View attachment 86842 View attachment 86843View attachment 86844 View attachment 86845
First very gentle (mot-less) drive around the block, All seems ok. Didn't blow up or have z brake failure.

Excellent, well done pal, did you have to compress the bushes and what springs are you on, they look like -40mm are the Apex

 

[Faheem]

Well done mate. I bet you must be relieved that it all worked after you put it back together i know i was!

Mine is in for an MOT tomorrow or Wednesday. Sadly I wont be taking it there so I won't get to see the look on the MOT testers face