Thread: Rebuilding Sid

Cheers guys,

Yes I think tolerance is too big, it’s about 1/4 mm which would allow vibration leading to bearing failure.

Plan A is to modify a 3 arm puller by making extended links from flat bar, but I suspect plan B (cutting nearly through and cracking then off) is more likely to work. I’ve ordered new collars and distance pieces so all three bits can be cut.

Putting them on, the manual says to drift them on with a tube

I think I may have discovered why Sid was cheap.

Decided to start taking lids of the various parts of gearbox to paint and change gaskets. Then my suspicious nature began to question why the transfer box oil was sparkly clean when every other drop of oil on this car has been treacle. A further look is making me think this box was full of water at one point...or mud.



So I’ve removed the transfer case and getting a better look. Doesn’t look too bad but I think there is a problem in the front drive box. Backlash on the gears on the shaft is about an inch. End float can be measured with a ruler.

Gearbox rebuild here we come.... looking forwards to this!

Rebuild well underway and this is incredibly satisfying stuff....I’ve started on the transfer box



Front housing cleaned and clear-coated



Same for the box itself.



Ready to go back together. Now this reminds me of the game I had as a kid called Buckeroo.... carefully trying to add bits to the box... one wrong move and it all explodes.



Done and all works. I’ve got the other bits and pieces in paint and will finish it off tomorrow. Then onto the gearbox itself.

Gearbox!



This is a bit of a mess, leaking a fair bit.



Not helped by the liberal use of gasket cement around every joint. The clutch release housing was glued on and took a fair bit of shifting.

All cleaned out now, parts washing and then paint stripper to remove the old gasket cement.

It does mean that I’m in for new bearings unfortunately.

Inside of the gearbox is spotless, but the oil is yellow/gold. Not sure if to worried yet. I’m in this far so will strip rest of box down.

I did take the lid off....

Then carefully replaced it.... that’s for another day.

Felt brave this evening and decided to keep going with the box.



Selectors removed, all the loose bits are taped in and I’ll clean these up one by one.

First problems, as I had thought, this box has been full of water at some point. Granted someone has cleaned it up but ...rust


Think first is toast...

The main shaft looks better, no damage visible, but this isn’t good



Third gear is a bit wobbly, end float is 0.025” (should be 0.004-008” According to manual). Second gear has no end float, can’t get anything in.

Drift out main shaft.....err right



So far so good, but I’ve reached the snap ring. Time for dinner..

“Well there’s your problem!!!”



Instincts were right....there was a problem deep down. That was a one piece bush. Huge relief to find that.

When I was bench testing the box it all seemed to work fine, changed gear, no unpleasant noises, but the cleanliness of box and oil and the yellow colour did not feel right.

The only physical sign (part from oil) was that end float.

Thats a common break. Ive seen a couple like that

With the break in the weather I’ve finally been able to get Sid out in the sun for a wash and final coat of paint.



The front end finally came together this week with the arrival of OEM half shaft bearings from paddocks. Huge difference from the Brit part ones that I started with, for a start they were the same size as the old ones!





So, Sid is now back in the shed and next up is the gearbox

One gearbox cleaned, disassembled and ready to go



I’ve a complete rebuild kit coming from the UK this week. I am looking forward to this, it’s been great fun so far.

Would it be if interest if I video’d the build? I’ve been using the only YouTube vid I can find if a box rebuild but that was a series 3.