Series3100's S3 88" rebuild...

[biosbill]

Originally Posted by Mseries3

Brake Cleaner... Wonderful stuff and does not damage paintwork!

I use that for everything too !

William

[series3100]

Went for the lighter fluid option. I got most off (of what i tried too) so i'll give it another go and hopefully get all the stickiness off second time round... I didnt even bother trying to get the tape off the windscreen, thats for another day.

Anyway i'v attached some pics, defiantly looks better in the pictures than reality though.

Brian

[series3100]

Went and took the rear diff out of the 90 earlier - I thought it was knackered as the 90's running gear has LOADS of play somewhere but the diff has actually got next to none, far better than the series diffs. That thing is flippin heavy... to be lying underneath, not looking forward to fitting it.

I'v clean it, degreased it and now its in red-led waiting for a coat of black.

Brian

[sniff my diff]

They do weigh a bit dont they

Mark

[series3100]

Originally Posted by sniff my diff

They do weigh a bit dont they

Mark

I knew it was going to be heavy but wasn't expecting that much weight on my chest! Bloody awkward thing to get out. 3 more to take out (front from 90 and both from series) then got to get them into the series axles... One thing i have noticed though which is a bit of a bonus is i wont need to add oil filler holes to the axle casings (which is the case with a lot of series axles) because it seems my late(ish) series axles already have the filler hole in the diff pan.

Brian

[fosters ice]

think if i was you brian i would keep the std diffs in as if you fit the 90 diffs your landy will be too layed back without the turbo fitted.

graham
__________________
1962 2a swb 200 tdi.
1997 disco 1 300 tdi.

[series3100]

I just wrote a really long post then closed the internet by accident.

Originally Posted by fosters ice

think if i was you brian i would keep the std diffs in as if you fit the 90 diffs your landy will be too layed back without the turbo fitted.

graham
__________________
1962 2a swb 200 tdi.
1997 disco 1 300 tdi.

I'v talked to someone with a Di and someone with a 2.25p who both have 3.51 diffs and it seems ok + once its MOTed and i'v got nothing else to do the turbo's going back on anyway.

Instead of lying under the diff, sliding it out then lowering it onto my chest I got in some weird cramped kneeling position above it and found it much easier to be above it and lower it down. With my new (slightly less damaging) technique it was really easy. From starting off so removing the prop and half shafts, removing old diff, fitting new and bolting everything back up and ready to go took 1h15 so was a lot lot quicker and easier than i expected.

We took it for a spin to try it out and 1st is now much more car like. Going up a hill it still pulled up in 4th only faster and if you dropped down to third it accelerated very well. Its all a lot quieter! It was a bit wet when we went out but the goodyear wranglers were pretty impressive under braking, a lot better than dad's 90 was on similar tyres. Seeing as things we mostly working this time we were having a bit of a play and the gearbox seems pretty nice, giving it some welly it slips into every gear easily and no weird noises or whining either i dont think. The only problem now is the steering Beyond the steering box EVERYTHING has been replaced and is nice and tight but the box it's self is causing a bit of trouble. I jacked the front up and if I tighten the box up it just makes everything stiffer but there is still a good 2" play at the steering wheel. It's defiantly in the box because I can turn the steering wheel and the arm on the box doesn't move. Are there any other ways of removing play form the box? Shims i can remove maybe? Discuss please. The other thing i noticed with the steering is the bearings at the top of the column are completely past it - The wheel wobbles in all directions so im going to have to sort that too which is a bit of a PITA.

Other than steering I'm very pleased.

Brian

PS I have a pair of rear half shafts and flanges from the 90 that have only done 3000 miles if anyone's interested?