Oh dear! Loud bang and clatter racket.

Finally got some more time in the shed, by virtue of some last minute cancelling of other plans I had.:(
I didn't get any photo's of the gearbox going back together. It's a bit tricky trying to get everything to line up, often needing three or four hands, and hold a camera. I did get a few photo's today of getting the transfer box bolted up.
So first up the transfer box is slid up to meet the back of the gearbox. Simply align the studs and bolt them up. Then unbolt them, pull the transfer box off again and this time put the gasket in between:mad:.:D.

While the gearbox is lying on it's side to make it easy to fit the intermediate gears back in, I took a little extra time to remove all the studs for the transfer box bottom plate and clean them up a bit. So first photo is the transfer box empty except for the output shaft, because I never took the output section off:
https://www.aulro.com/afvb/images/im...12/02/1320.jpg

Next photo I have the gearbox main shaft fitted with the transfer gear, the end plate bolted back on and the intermediate gears fitted. Just half way through refitting the studs for the bottom plate. I cleaned up each thread of the studs and refitted them with loctite. When I was dismantling I found most of the studs came out when trying to undo the nuts only, so I figured they'd never had loctite or been torqued.
https://www.aulro.com/afvb/images/im...12/02/1321.jpg

Bottom plate all bolted on and nice and clean. I decided not to bother repainting anything, so just cleaned everything pretty well.
https://www.aulro.com/afvb/images/im...12/02/1322.jpg

So now it's virtually ready to go back in. The mount brackets are on but I still have to reattach the drum brake assembly. I want to track down and replace the small rubber "seal" on the handbrake actuator as it's been letting oil and dirt into the brake housing. I have some new handbrake shoes to fit but don't want them trashed because of not replacing the seal. Anyone know a part number and where I can get one from? (I haven't actually looked myself yet - just seemed easy to ask while I'm here;)).
https://www.aulro.com/afvb/images/im...12/02/1323.jpg

https://www.aulro.com/afvb/images/im...12/02/1324.jpg

I mentioned my new "garage toys" a while ago. Meet the new "teardown table". It's been very, very useful and it's sooo great to not be crawling around on the ground while dealing with big heavy parts like a gearbox. In the background is the engine crane, levelling bar and the 1.6 LR engine is mounted to the engine stand. Gotta love Christmas ... the ultimate excuse to buy workshop stuff!:p
https://www.aulro.com/afvb/images/im...12/02/1325.jpg

So hopefully next weekend I'll get to start looking at checking adapter plate alignment. I'll try to get some good photo's of that, as I haven't really come across any myself and I'd love to see some so figure others must too.

Ciao
John B

Dust cover for expander unit 515466. Not sure how it will let oil in - should not be any oil on the outside! But it is needed to keep water, mud and dust out of the actuator.

Oil will usually get onto the brake shoes from a leaking rear seal. If you have not replaced this, it is probably a good idea. But note that there is a slot machined on the surface the brake backing plate to allow any oil leakage to drain outside of the backing plate. Make sure that you do not block this when assembling the handbrake, and check it is clear every service.

On your comment about the bottom plate studs not being loctited - it might be worth noting that this box was designed (1947) before the invention of loctite (1953), and almost certainly made before its use received widespread acceptance (about 1970 - 1980).

John

[/QUOTE]
That explains the small cover plate [/QUOTE]

Under that plate don't use the full sized gasket for the early model, as the early plates are a complete oval, but make yourself another gasket that is the same shape as the later half size plate.


With the other gaping holes that may be there, try and get the appropriate grommets, even if you can't make it completely water tight, it should slow it's demise in a creek crossing.
Sorry if you have already done this work, but water when it gets in, it doesn't do the clutch plate much good, the after effects can range from a slipping clutch and a red face to; a gearbox full of water, ruined throw out race, dead motor, the esky floating down the water way, wet very grumpy passengers and someone doing CPR on the driver.
.

Quote:

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Originally Posted by JDNSW

Dust cover for expander unit 515466. <snip>

John

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Land Rover Series 1 - 3 Handbrake Actuator Boot | eBay

Great thread, really informative. Putting this all to 'future reference'.

Quote:

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Originally Posted by JDNSW

Dust cover for expander unit 515466. Not sure how it will let oil in - should not be any oil on the outside! But it is needed to keep water, mud and dust out of the actuator.To be honest, it's an assumption that the problem is oil getting inside. There is generally oil all over the brake drum, and I suspect it might be from the output shaft seal, and regular application of the handbrake while driving seems to make the brake work better for a few days - ie maybe until the oil re-soaks into the brake shoes.

Oil will usually get onto the brake shoes from a leaking rear seal. Yep - that's what I suspect. If you have not replaced this, it is probably a good idea. Yep But note that there is a slot machined on the surface the brake backing plate to allow any oil leakage to drain outside of the backing plate. Make sure that you do not block this when assembling the handbrake, and check it is clear every service. This is news to me. I'll check it when I actually take the drum assembly apart for a clean-up and to instal the new brake shoes.

On your comment about the bottom plate studs not being loctited - it might be worth noting that this box was designed (1947) before the invention of loctite (1953), and almost certainly made before its use received widespread acceptance (about 1970 - 1980).Fair call, but the gearbox has been overhauled only a couple of years ago. (There was a receipt in the documentation I got with the car - it's part of the reason I paid so much for the car ... we're all allowed to make mistakes.:()

John

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Quote:

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Originally Posted by wrinklearthur

Under that plate don't use the full sized gasket for the early model, as the early plates are a complete oval, but make yourself another gasket that is the same shape as the later half size plate.I just shot out to the shed to check and sure enough, I used the old full gasket. I see why you say not to use it as it leaves a small gap at the back/bottom where the half plate stops and the full gasket doesn't. I'll take some photo's of the gap and the difference when I fix it up.


With the other gaping holes that may be there, try and get the appropriate grommets, even if you can't make it completely water tight, it should slow it's demise in a creek crossing.The rubber grommet around the clutch actuator shaft is pretty bad but the shape is generally there. I think a good dollop of silicone will help - if I can't easil get a replacement to fit.
Sorry if you have already done this work, but water when it gets in, it doesn't do the clutch plate much good, the after effects can range from a slipping clutch and a red face to; a gearbox full of water, ruined throw out race, dead motor, the esky floating down the water way, wet very grumpy passengers and someone doing CPR on the driver.That doesn't sound like me at all!!! Honest!!!

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Thanks so much for your feedback guys. Gotta love this place!:cool:
Cheers
John B

Quote:

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Originally Posted by JayBoRover

The rubber grommet around the clutch actuator shaft is pretty bad but the shape is generally there. I think a good dollop of silicone will help - if I can't easil get a replacement to fit.

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The place I linked you to for the actuator boot - check him out for the grommet around the clutch actuator shaft - he used to carry spares for them (that's where I bought mine from).

Hi Jaybo.

Just realised you're that nice fella with the even nicer white 450RR. We met at Safari a few months back when I was doing work for GHR. :D

Quote:

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Originally Posted by drifter

The place I linked you to for the actuator boot - check him out for the grommet around the clutch actuator shaft - he used to carry spares for them (that's where I bought mine from).

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Hiya John.
Yep, both are on order. I had to restrain myself from buying other stuff when I looked at his eBay shop. Have to keep reminding myself of my upcoming Dakar costs.:eek:

Quote:

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Originally Posted by MacMan

Hi Jaybo.
Just realised you're that nice fella with the even nicer white 450RR. We met at Safari a few months back when I was doing work for GHR.

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Heh heh. Small world isn't it mate. I remember chatting to you, with the camera always within reach;). The other half of the shed where I'm working on the S2a gearbox is the 450RR:cool::
https://www.aulro.com/afvb/images/im...12/02/1220.jpg

Cheers
John B

Quote:

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Originally Posted by JDNSW

Dust cover for expander unit 515466. Not sure how it will let oil in - should not be any oil on the outside! But it is needed to keep water, mud and dust out of the actuator.

Oil will usually get onto the brake shoes from a leaking rear seal. If you have not replaced this, it is probably a good idea. But note that there is a slot machined on the surface the brake backing plate to allow any oil leakage to drain outside of the backing plate. Make sure that you do not block this when assembling the handbrake, and check it is clear every service.

On your comment about the bottom plate studs not being loctited - it might be worth noting that this box was designed (1947) before the invention of loctite (1953), and almost certainly made before its use received widespread acceptance (about 1970 - 1980).

John

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I opened up the handbrake drum and found everything completely soaked in oil:eek:. I think there was more oil in the handbrake drum than in the gearbox:D! So I cleaned everything, replaced the brake shoes and replaced the dust cover for the expander unit. (The rubber bits arrived today).

In the weekend I also discovered that the handbrake shoe kit also came with the replacement transfer box outlet seal, so that got changed too. Hopefully my new brake shoes will stay nice and clean and dry from now on. (Of course they will at the moment ... the entire gearbox, transfer box and handbrake drum are sitting on the workbench:p)

I did find the slot that is supposed to allow any oil that has escaped from the transfer box rear seal to escape before reaching the drum brake. It was clear and quite large, so not a problem.

Some photo's this weekend.
Ciao
John B