Thread: Series 3 Rebuild.

Originally Posted by TJWA

Then... the unthinkable... well no actualy, it is a Series so anything is possible. The starter motor **** itself. I didn't want to muck around with anything second hand so I ordered a new one straight away for the holden 6. It arrived and I went to put it in. I noticed the two bolts holding the old one had become loose....I tightend then instead of changing it out and low and behold it started fine again! No problems!

Had exactly the same experience with a Peugeot 504 many years ago. The starter motor engaged intermittently and it would start, but the rest of the time it spun without engaging, and it sounded just like when a solenoid doesn't kick hard enough. I only discovered the cause - loose bolts - when I went to fit a new starter.

The good part was I had purchased the car cheap because it wouldn't start.

what about the hemi 6 combo you have?

Originally Posted by hillbilliywheelchair

what about the hemi 6 combo you have?

I spoke to Agrojnr and he said the box is not perfect on that one either.

I got the high ratio transfer case yesterday, stripped the old transfer case and have almost switched it over. I'll finish reassembling the gearbox and TC on Friday and will hopefully have it all back in this weekend. Can't wait to see what it's like with the new high ratio and a rebuilt gearbox.

and i knoe you dont go any where else but the series 3 section so i'll post a link hear for you

http://www.aulro.com/afvb/wa-aulroia...h-nov-bbq.html

and i hope it all goes well for you so you can get on with the 88

Hi Travis
If you need shims for that transfercase and cant get any in Collie(that bearing shop is VERY good if its still open) I have some you can have left over from when I did mine up.
Yell out if you need them,I will dig them out.
Andrew

Originally Posted by LandyAndy

Hi Travis
If you need shims for that transfercase and cant get any in Collie(that bearing shop is VERY good if its still open) I have some you can have left over from when I did mine up.
Yell out if you need them,I will dig them out.
Andrew

I'm guessing you're talking about the two brass tagged shims on either end of the intermediate gear? The High Range Transfer Case came with a new one stuck to the inside of the front of the box and I have a fairly good one for the rear that doesn't look as though it has lost any flesh. There is still a bit of play in the gear though and I'm wondering if this is acceptable. I'll check the manual.

It will be interesting to see how this box goes as it's made up of two S3 boxes and one S2A!

They go on the intermediate shaft.
These are plain shims to stop sideways movement if there is any with the new brass shims fitted.
If you have a noisy TC in a series its usually the intermediate shaft that needs shims.
Andrew

Originally Posted by LandyAndy

They go on the intermediate shaft.
These are plain shims to stop sideways movement if there is any with the new brass shims fitted.
If you have a noisy TC in a series its usually the intermediate shaft that needs shims.
Andrew

Thanks for that. I read the manual and it said I needed 0.1 - 0.2mm of play, I had 0.53mm. As much as I would love an excuse to drive the Porsche and come and see you I went down to the local bearing place (yep, the good one) and bought some shim stock as it's called which is just thin sheets of metal you can make into shims. I made a 0.15mm and a 0.25mm shim by cutting them out with scissors then getting two spare thrust washers, clamping them togethor in a vice and filing them to size. Worked a treat and I ended up with the right amount of play.





I then had the dilemma of trying to get the rolling resistance of the output shaft between 0.9 - 1.8kgs as the manual states. Have you tried buying a spring balance lately!?!?
I came up with the below idea which worked well, I knew those weights would come in handy one day. ;-)



And all back together ready to go in. Woohoo 110km/h here we come!