Isuzu C240 powered Series 3

Charging problems turned out to be a dodgy contact in the ignition switch, wriggle the key a bit and it comes good.
Starts very easily now. Cold give it about 10s of glowplugs then push the shut-off knob and it fires up very quickly (with a lot of smoke), warm it starts without glowplugs or overfueling.

Changed the oil and filter.
The filter on the C240 is a cartridge type but upside down so you have to remove a drain plug on the underside to empty the housing then remove the housing & filter from above. Element was readily available because it also fits an early Rodeo.

I've left the coolant for the time being, once I get the gearbox back on and it moves under it's own power I'll change a few hoses and replace the coolant then.

Replaced a couple of globes, all the lights work now. I just need to track down why the horn doesn't work.


Colin

Decided to take the doors off for repair today.
The passenger side door top is rotten and the PO had removed the glass and taped a sheet of platic over it to try & keep the weather out.

https://www.aulro.com/afvb/images/im...12/07/1101.jpgDSCN1303 by Colin Radley, on Flickr

The plastic had kept the water in and helped it rot faster.

https://www.aulro.com/afvb/images/im...12/07/1102.jpgDSCN1306 by Colin Radley, on Flickr

I was trying to do the job single handed so this adjustable stand came in handy.

https://www.aulro.com/afvb/images/im...12/07/1103.jpgDSCN1308 by Colin Radley, on Flickr

Replacement door fitted (complete with Leyland badge). The door lock is broken and there is a tear in the skin but it will keep the weather out for the time being.

https://www.aulro.com/afvb/images/im...12/07/1104.jpgDSCN1312 by Colin Radley, on Flickr

Need to work on the other side looking at the growth in the runners.

https://www.aulro.com/afvb/images/im...12/07/1105.jpgDSCN1313 by Colin Radley, on Flickr

Next I started on the gearbox and drained a few lumps out that shouldn't be in the oil. More on that later......


Colin

The items in the picture below came out with the gearbox oil (not the keys !)

https://www.aulro.com/afvb/images/im...12/07/1058.jpgDSCN1326 by Colin Radley, on Flickr

Fortunately I'm still in contact with the PO and it turns out that they fell in while he was removing the gearlever :)

He did also get bits of synchro spring come out with the oil so the box is getting stripped down anyway.


Colin

Cleaned the gearbox up ready for stripping down.
Broken synchro spring is a known problem but I'll check everything out while It's on the workshop floor.

https://www.aulro.com/afvb/images/im...012/07/793.jpgDSCN1346 by Colin Radley, on Flickr


Colin

Had an hour or so tonight to work on the gearbox.
I've scanned the pages out of the Haynes manual and laminated them (a bit anal but I'm sure they'll come in handy).

The top gearbox cover came off first. Then I stripped off the handbrake drum, backplate etc. To undo the output flange nut I removed the interlocking plungers so I could select a forward gear at the same time as reverse to lock the gearbox. The last person to work on the box must have been worried about this nut coming undone because I had to use the longest breaker bar I could find.

https://www.aulro.com/afvb/images/im...012/07/767.jpgDSCN1351 by Colin Radley, on Flickr

https://www.aulro.com/afvb/images/im...012/07/768.jpgDSCN1349 by Colin Radley, on Flickr

The nut holding the mainshaft gear for the transfer box has been removed & refitted using a cold chisel. The Haynes manual shows an 'alloy drift' being used. I might have to make up a tool to do the job properly but I'll have to replace the nut.

https://www.aulro.com/afvb/images/im...012/07/769.jpgDSCN1350 by Colin Radley, on Flickr


Colin

Hi Colin

The end of that shaft where it runs in the needle roller in the cover, looks a little less than polished. :(

Fingers crossed, We are going to the accountant tomorrow. Will we have enough of a refund to escape from the convict isle ? --- with a trailer !!!!! :p
.

Quote:

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Originally Posted by wrinklearthur

Hi Colin

The end of that shaft where it runs in the needle roller in the cover, looks a little less than polished. :(

Fingers crossed, We are going to the accountant tomorrow. Will we have enough of a refund to escape from the convict isle ? --- with a trailer !!!!! :p
.

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Arthur,

I'd noticed the grey rather than polished end to the shaft. This isn't going to be used for high Kms and will probably end up on club plates so not worried at this point. It has supposedly been rebuilt but the chisel marks on the nut for the mainshaft gear in the transfer box make me wonder who actually did the job....

I'll make up the spare bed if you're coming over with a trailer....

Colin

Progress is slow on the Land Rover(s) at the moment.
Just spent the weekend adding Lilydale Toppings to the driveway to replace what was washed away earlier this year, cutting grass and dozens of other jobs around the house.
I did get Walit started yesterday, easy now I know the procedure. I also started and ran the Series 2 109" to dry it out and throw some oil around the engine.

Managed to find some time tonight to get the cover plate off the transfer box and remove the intermediate gear cluster. Also degreased the parts I've stripped off so far.
Must get round to orderings some spares for the handbrake mechanism. The expander is badly worn and some of the retaining clips were missing.

https://www.aulro.com/afvb/images/im...012/07/516.jpgDSCN1359 by Colin Radley, on Flickr


Colin

Quote:

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Originally Posted by gromit

Progress is slow on the Land Rover(s) at the moment.
Just spent the weekend adding Lilydale Toppings to the driveway to replace what was washed away earlier this year, cutting grass and dozens of other jobs around the house.
I did get Walit started yesterday, easy now I know the procedure. I also started and ran the Series 2 109" to dry it out and throw some oil around the engine.

Managed to find some time tonight to get the cover plate off the transfer box and remove the intermediate gear cluster. Also degreased the parts I've stripped off so far.
Must get round to orderings some spares for the handbrake mechanism. The expander is badly worn and some of the retaining clips were missing.

https://www.aulro.com/afvb/images/im...012/07/471.jpg



Colin

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What are the intermediate bearings like? How about a pic next to a straight edge to see how twisted they are... :D

Quote:

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Originally Posted by isuzurover

What are the intermediate bearings like? How about a pic next to a straight edge to see how twisted they are... :D

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Do you mean the needle roller cages ?
They were a bit 'floppy' but still holding together.....just.
I popped them back inside the intermediate gear cluster and put the shaft back in just in case they fell apart

Colin