Thread: Isuzu C240 powered Series 3

Motor is free, took a bit of effort on the front pulley nut to turn it over but at least it's not seized.





Nice extractors.....





"OK 85-95psi" probably from when the motor was purchased ?






Colin

I took the brake pedal box out at the weekend, now I have to either repair or replace the brake servo.
I have an overhaul kit for the master cylinder but the servo looks very old and past it's use-by-date. It may work but the vacuum connection/non-return valve is crumbling away, the body is in poor condition and the master cylinder end doesn't look too healthy.
Currently investigating overhaul vs. pattern replacement.
I'll have to add it to the list of parts needed from the UK.

Rear propshaft turned out to be OK, no play in the UJ's or the slip joint. Just giving it a coat of paint a new slip joint seal and a protective boot. Then off with the front propshaft for the same check.

List of work to be done (I'm sure I'll find some more things .....)

Repaint pedal box
Overhaul brake master cylinder
Order parts from the UK - seats, seatbelts & servo.
Repair door bottoms, paint door bottoms.
Paint and fit replacement door tops
Replace radiator & hoses
Replace windscreens.
Panel beat or replace the front wings
Respray

Another bargain Landy that costs a fortune to get back on the road. I hope the Isuzu motor gives a reasonable performance after all this work !


Colin

Rear propshaft is back on and front is off for checking.

The brakes were working but everything else in the braking system has been checked so while the brake servo is away being reconditioned I thought I'd overhaul the master cylinder.






No problems internally so just needs a cleanup & a seal kit put through it.
The reservoir isn't in great condition, they all seem to suffer on one side from UV where the gap between the bonnet & wing allows light through. The previous owner had covered this side with tape but once lifted off there are a lot of cracks in the surface. I have another one that has started to crumble to dust so I'll have to get a couple of replacements.


Colin

I'm just putting together a couple of orders for the last parts I need for Wallit from the UK (plus some spares for stock). Once I get these the final items will be the windscreens, wings & doors. I think I'll put another advert in Markets.

I had Wallit running at the weekend and the engine (and the rest of the car) vibrate a lot at tickover. Once the revs are increased slightly it all settles down. I replaced the gearbox mountings but I'll have to check the engine mountings (or raise the tickover !). There are a lot of cracks in the front wings which may have be caused by the vibration.
I took it for a quick run down the driveway and the acceleration seems OK but the final proof will be when it's back on the road.....


Colin

The servo is on it's way back from Hydroboost. Fully reconditioned for $217 including return freight.
http://www.hydroboost.com.au/

Terry told me it was the worst condition servo that he has repaired rather than thrown away.
He phoned up early on to let me know that they could linish the outside to remove the rust pits. I declined because it's going to be a working car rather than a show car. The push rod one end was damaged, studs were loose, diaphragm past it's prime etc. etc.
I'll post a before and after photo when I get it back.


Colin

Pedal box is back together waiting for the booster to arrive.
I'll make a gasket from an inner tube for where it seals against the bulkhead.






The front driveshaft has been repaired at some point in the past. A new splined section has been welded in.






The splined section had been pulled out of the seal somehow. The seal (cork) had the shape of the splines in it and the split washer has been pulled out through the screw on holder. I flattened the washer out but there is no way it will go back in place without a lot of work so something else on the shopping list. Problem is it doesn't show up in the parts manuals so I might have to visit a propshaft repairer and see if they can help.



Colin

Booster turned up yesterday.

New pushrod installed, studs welded back in, new non-return valve, new diaphragm etc. All done for less than the price of a pattern part.

Before




After





Must get onto ordering those last parts from the UK.


Colin

Fitted the brake pedalbox and servo this weekend.
Must get that order off to the UK because I need a reservoir for the brake master cylinder.





Just looked at the picture and I must remember to spread that splitpin.


Didn't get much time for anything else, but I did chase after a couple of 'spares' cars.
Series 2 wagon that was driven round Australia 15 or so years ago then parked up outside. Full of rat **it and the smell......
All four front doors in brilliant condition. Home made 'tropical high roof' if you want a bit more headroom in the back. Bulkhead past saving, high ratio diffs, wrapped & greased springs and a few other gems.
Series 2 LWB ute. Tree recently fell on it. Parked up under trees years ago but again quite a few bits worth saving.
Heading back in a week or so with a toolbox and some cash.


Colin