1st July - Brakes fixed and suspension loaded

BRAKES

 After having decided a few weeks ago that the rear brake snail cams were worn so far that they wouldn't allow the shoes to be adjusted up against the drums I then find that was not the reason for their lack of adjustment.

The new  'snails' had arrived and I proceeded to fit these and then found I had the same problem (though at least the new cams weren't worn smooth).

What I then realised was the rear brake shoes were slightly different so they must be trailing and leading types - though the green bible or Haynes or anywhere else said nothing about that. So I pinged an enquiry on the Series 2 forum and DavidTS pointed to part of Teri-Ann Wakemans informative site which says just that!
                              
http://www.expeditionlandrover.info/landRoverFAQ/FAQ_rearbrakes.htm

So now the brakes are assembled as Teri suggests and they work fine. So all those with a 109 - take note!

Note the difference in the brake shoes in my pic below. The leading shoe is the top one.

 

SUSPENSION

There are alternative methods of loading the suspension before tightening the whole lot up but wrapping a chain around the chassis and compressing it seemed like a ripe way to damage the paintwork and galv so I thought of another method.

In the front seats I dropped in a two spare 750's plus around 80kg made up of bins full of water (about the weight of 2?). Then to the rear a further 500kg of water in dustbins and buckets. Should be enough meethinks?

Suspension then tightened up. So that's another two jobs crossed off.

A quick run out proves everything is working fine (though the base of the Larkspur antenna became unbonded on the way home).

 

Next task is to set the headlights angle and fit the bumper.....and book an MOT.

 

18/19th June - Few MOT bits fixed

I came home for a 3 day weekend with a backlog of chores to do. Even then a few small jobs were struck off on Trig.

From the last post there were a few problems that need resolving for the MOT.....

• INDICATORS - Problem now resolved by replacing the front Lucas 594 metal lamp housings.
• SPEEDO NOT WORKING - Fault found to be the flexi drive shaft end that engages with the speedo at the rear. The bush fitted over the shaft had moved preventing it from fully engaging with the drive gear in the head.
• BRAKES - see below
• SUSPENSION - still needs loading and torquing up.

BRAKES

The run out the other week showed that they work but I felt they should be a bit more solid in their action. So I already thought one of the lefthand rear shoes was not adjusting up correctly anyway and stripping them down showed why.....the snails cams were worn past the point they actually worked!

So a new set is on order and will be ready to fit when I get back from this job towards the end of June.


BUMPER

Rob has donated his old ex-mil bumper from his S3 but the overriders need to come off and are being a 'bit' stubborn. Front bolts had to be disked off but the 8 internal ones will need a different approach. They have been soaked in WD40 for several days and I have a couple of new 9/16 ring spanners on order. This is the only means (plus drop in a touch of extreme swearing) other than a good application of a gas torch, that will get them off.

Once off I will fit the bumper 'as is' for the MOT, then remove and arrange repair (bent at one end) plus sandblast and maybe re-galv along with the correct and original overriders.

DASH/INSTRUMENTS

Well I said that that side of it was complete but prowling 'The Bay' a few weeks ago I found a supplier (Green Oval Land Rovers) that manufacturers and sell a copy of the original painted and embossed brass labels to fit over the Lucas toggle switches. So I ordered a few including a 'heated front windscreen' one ;)

...and the priority 1 task was fitting the bridge plate. Tick that one off :)

I am now away again for a few weeks but on my return I will get the bumper on; the brakes fixed and the suspension set. Then I will go for a run and see how that goes. If it goes to plan then I will schedule the MOT!