Silverbullets' resto: Engine, gearbox, suspension

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Silverbullet
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Re: Silverbullets' resto: Engine, gearbox, suspension

Post by Silverbullet » Tue Nov 09, 2021 10:03 pm

Denzil, you are right about the little tabs/holes for the cowl panel going into the cab but I had already addressed these with the silicone solution.

Yesterday I got the rear axles back from rebuild, they looked brand new and I couldn't wait until the weekend so I got them in the car soon as I got home from work. This was probably a mistake, took close to 3 hours and I ended up dropping the diff to get them in since they are about 3mm too long to get them in with the rear end intact. Then I get this thing where when I'm on my back under the car and turn my head a certain way my head starts spinning and I get nausea, by the end I was so tired from heaving the diff around, sore all over and close to hurling from the nausea :cry:

Today on the drive in to work 2 things became apparent:
- 3rd gear in 2WD now has a new grinding noise, a very metallic noise almost like the shifter linkages clanging together but it is definitely inside the gearbox. The noise gets worse if I push the gearstick "further in" towards 3rd gear. Further proof that this gearbox is scrap and I need to replace it soon.

- There is a very noticeable and un-pleasant vibration throughout the whole car at about 90-100 km/h and above :neutral: Have no idea what could be causing this, I thought maybe the diff has no oil (can't remember if I put any in it was too long ago :oops: ) but there is no diff noise and it wasn't hot when I finished driving.

So slightly disappointed with the whole situation now the rear axles are in, I was looking forward to getting out onto some tracks with it but can't do so with confidence with these issues :(

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TOONGA
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Re: Silverbullets' resto: Engine, gearbox, suspension

Post by TOONGA » Wed Nov 10, 2021 10:06 pm

Sam is the tail shaft a single piece or dual piece tail shaft?

It could be a tail shaft vibration either way.

As for the gearbox I saw the video on facebook but had no idea of what was wrong.

I'm thought the syncro has gone on 3rd but Subarino thinks it is linkages

TOONGA
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El_Freddo
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Re: Silverbullets' resto: Engine, gearbox, suspension

Post by El_Freddo » Thu Nov 11, 2021 6:29 pm

I think the universe is telling you it’s time for a 5 speed box ;) ;)

Bugger about the head spinning thing. Have you checked that out with your doc? Might be worth looking into if you haven’t already.

I hope the vibration isn’t the rebuilt CV shafts!

Cheers

Bennie
"The lounge room is not a workshop..."
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Silverbullet
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Re: Silverbullets' resto: Engine, gearbox, suspension

Post by Silverbullet » Thu Nov 11, 2021 8:25 pm

TOONGA, it's a custom single piece tail shaft. I think it must be either the tail shaft or the rear axles so on Saturday I will get the car up on 4 jack stands, idle in gear and 4WD so the rear wheels spin and have a look underneath, see if anything is wobbling or has run-out. The other thing I thought it could be is if the g/box and diff inputs/outputs are not aligned correctly or at the same angle, I've read this can cause big problems. Might need to take it to a drive line specialist to check if it's all aligned correctly. I topped up the diff oil, it was low but not empty. Didn't make any difference to the wobble.

And yes Subarino Dave to the rescue, I think he could be right about the linkage hitting the tail shaft (it sure sounds like that) I'll check that too on Saturday.

Bennie, it IS a 5 speed box! :lol: The gearbox I got years back for $200 from Rising Sun Steve when he was rebuilding the engine, back when the wagon was still driving around in its old (silver) form! That was a long time ago. It does need replaced though, I'd say 50% of the noise that comes into the cabin comes from the gear box whining and whirring, 2nd and 3rd gear syncros are toast as well. Yes the oil is up to the full mark :roll:

The dizziness started after I got labyrinthitis one easter weekend a few years ago. That has to be the worst 5 days of my life, felt like my head was being twisted off my shoulders. It caused some damage to my inner ear/vestibular organs I found out later.

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Silverbullet
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Re: Silverbullets' resto: Engine, gearbox, suspension

Post by Silverbullet » Sat Nov 27, 2021 10:37 pm

A little update, some good(ish) and (very) bad updates and things I've noticed. But first a pic from today's adventure, a day trip down to Goolwa beach (a 4WD only beach) the first time I've really used the 4WD system since the resto and the new axles. It wasn't exactly difficult, you could get a corolla down that beach easily I think but it was still fun and the 4WD works really nice.

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The vibration that appeared after installing the rear axles seems to have died down a little, it's still there but not as violent or annoying as it first was. This makes me think maybe something is up with the rear diff which is working its way out slowly. The diff is from an L touring wagon I bought for $600 and promptly scrapped many years ago, who knows what condition the diff was in and it has been sitting doing nothing for 8 years or more.

The (very) bad news is I've noticed another leak in the engine bay, probably the worst one that could happen. There's two bolts on the top of the engine block under the intake manifold that hold the block halves together, one going in from either side with a little depression in the block casting for the bolt head. In this depression some weeks ago I noticed a muddy brown sludge forming under the bolt head. I thought some oil had dropped in there when I filled it. I clean it away but it re-appears, getting steadily bigger and now most of the top of the block is covered in a brown rusty stain that dries out (not oily) Then today I stuck my head in there again and there is a green puddle under the bolt heads :cry: It's coolant, probably leaking from the coolant passage that goes between the block halves at the top. It must be seeping past the oval shaped O-ring and into the bolt holes, then past the bolts washers and out to atmosphere and rusting the bolts in the process hence the rusty brown stain. To fix this requires completely dis-assembling the engine :cry: There's no water in the oil at all, which is one good thing I suppose.

Not sure what to do here, it doesn't make the car un-drivable yet but I noticed the coolant level goes down slowly so it must be more than a slight weep. Three options I think:

- Drive it until it leaks so bad I can't drive it any more
- Pull the engine out and take it to an engine builders to fix the leak (don't know if I can be bothered completely dismantling the engine myself)
- EJ swap, I've driven this car long enough now to know the fabled twin carb, twin port engine isn't the mighty monster I might have thought. The car is slow. It keeps up with modern traffic sure but my foot is flat to the floor in most situations. It does sound good though ;) I've got an EJ20 sitting around but no ECU, I had planned to put a Haltech on it and put it in the Brumby but maybe it belongs in the blue wagon now.

I'll mull it over for a while...

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El_Freddo
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Re: Silverbullets' resto: Engine, gearbox, suspension

Post by El_Freddo » Mon Nov 29, 2021 8:09 pm

5 speed already... I should’ve known that!!

That leak, considered removing all the coolant, fitting an average radiator (stay with me!!), block off/reroute the heater circuit to bypass. Then run seal up or something of the like. Not chemiweld!

Go for a VERY long drive and let the stuff do it’s thing. Then let it cool and do it’s thing. Once that’s done, drop the water concoction, clean out the remaining crap, swap radiators back to your good one and replace the coolant.

I don’t see any other way to fix this issue other than removing the bolt and trying to pack some sort of sealer on there then do the bolt back up good and proper - then hope for the best.

Or EJ it. Could get an impreza AWD box (more mods!) with the low range (1.447:1) and it should be about right for gearing with your tyre diametre. I like factory management cutdown jobs - easy to get parts etc and no need to spend more money on tuning. But that’s just me. I have three cut down looms - two EJ22e Gen1 looms. One in Ruby Scoo and another that’s bench tested and works without issue. The third is a new loom to me, a GT foz loom, untested and hoping it’ll work without any issues. Time will tell on this one!

Subarino can do a cut down for you at a cost. He does quality work but is also flat out atm! You’ll need a loom, ECU and matching intake with wiring (and ANY of the security if it has that, including the key for the transponder chip).

It’ll kind of suck if you go EJ in the wagon you planned to keep relatively stock...

Cheers

Bennie
"The lounge room is not a workshop..."
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