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  1. #141
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    Default Re: Prof's Rocky Thread

    It's been a while since posting on this thread. Less driving due to Covid.
    Anyway, done some 10k km trouble free driving and a grin on my face.

    Recently the joins in the transfer case and gearbox started to actually leak oil. Off to gearbox indy as it entails removal, take apart transfer case and new gaskets. Best left to those who know. This was about the 1st week of December. Had to fit a 2nd hand clutch plate (had one) as clutch plate was worn. As it was difficult to find another clutch we sent plate of for relining.Got vehicle back and all was well except they did not reseal the the 4WD lever where it attached to TC. And the clutch tended to slip. So will wait for relined plate to come back.

    Because of the leak I parked vehicle to attend to it at a later stage. Have bakkie to drive with. Indy phones me and says plate is back, let's fit it. Drove there and there was a noise from gearbox/TC. What now? Indy dropped me off and he also heard it and reckons it gears. As he has to loosen gearbox to fit clutch plate, I expected him to have look see what was wrong.

    When he brought back car he said he only fitted clutch and I might have to start looking for another gearbox. WTF Anyway I drove 45km home and during last 10km it sounded like somebody was pounding a large hammer inside the gearbox.
    Parked in the back of the store and made a dent in my beer stash.....couldn't even tell wife what was wrong. My 'baby' is bust......
    '98 Daihatsu Rocky 'The Kitty'
    '02 Daihatsu Rocky 'The Bully'

    "What can be asserted without evidence can also be dismissed without evidence."

  2. #142
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    Default Re: Prof's Rocky Thread

    So I could stew over the issue during the holidays. Took two days just to tell the wife.

    Obviously the gearbox had to removed as to see the issue. But I wasn't gonna trust the indy anymore and he would want payment for the work. So I had to remove it. Spoke to my neighbour and he said we can make a plan to get underneath the car with some space to work.

    So we tackled the job 2nd week of Jan this year.

    Attached pics shows how we done it. I towed vehicle to his yard with an A-frame.

    Hell, this box is heavy, took three of us to drop it down.
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    '98 Daihatsu Rocky 'The Kitty'
    '02 Daihatsu Rocky 'The Bully'

    "What can be asserted without evidence can also be dismissed without evidence."

  3. #143
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    Default Re: Prof's Rocky Thread

    With the gearbox out I phoned the indy and told him the issue. As he had worked on the box I thought I would at least give him the opportunity to open to see what is wrong. I had only one proviso, I stand there whilst it is stripped. Agreed and took it there.

    Split the gearbox from the TC. No issues in gearbox. When we removed the back plate from the TC the issue became apparent. The bearing's inner bush had come adrift. He swears that he never removed the bearing, but the inner bush was fitted wrong way round. Inner bush has lip that has to face towards the TC and this one was facing wrong way round. So inner gear shaft was not supported anymore and thus the sound of gear not running as they should.

    Needless to say bearing was damaged as well, so of to SKF I went. Expected special order, but no off the shelve item. Fitted and when turning box all sounded well.

    I have a box with serious gears though

    The photo of TC is from previous opening and one can see how bearing should be
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    '98 Daihatsu Rocky 'The Kitty'
    '02 Daihatsu Rocky 'The Bully'

    "What can be asserted without evidence can also be dismissed without evidence."

  4. #144
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    Default Re: Prof's Rocky Thread

    Sorry to hear. Sometimes you have to wonder about the so called experts.
    Last edited by Tom13; 2021/02/07 at 12:10 PM.
    Mitsubishi Pajero 3.2 D-ID GLX LWB

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  6. #145
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    Default Re: Prof's Rocky Thread

    So now to refit box. But I still have issue with slipping clutch. I had two options, replace pressure plate as I still had a used one or a new one clutch kit. As it is such a schlep to take out box opted to go for new clutch kit. Just couldn't find one in SA. So order one from Milner Off Road in the UK as well as gearbox mount. 302 with shipping. Ouch.

    Took three days to arrive with paying my dues to 'state capture'

    Borrowed a gearbox jack and refitted with new clutch.

    Drove quite a bit during past week and no noise from TC. Gears working as they should. Clutch also a dream, heavy duty as the clutch plate has an extra spring within the normal spring.

    So it seems I have dodged a bullet
    '98 Daihatsu Rocky 'The Kitty'
    '02 Daihatsu Rocky 'The Bully'

    "What can be asserted without evidence can also be dismissed without evidence."

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  8. #146
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    Default Re: Prof's Rocky Thread

    Lucky one, always nice to hear a potential catastrophe come right!

    Have you tried CNR motors, I used them when I was in George, really good people, the honest kind you don't find anymore.

  9. #147
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    Default Re: Prof's Rocky Thread

    Quote Originally Posted by Skylark View Post
    Lucky one, always nice to hear a potential catastrophe come right!

    Have you tried CNR motors, I used them when I was in George, really good people, the honest kind you don't find anymore.
    Thanks. Will keep them in mind
    '98 Daihatsu Rocky 'The Kitty'
    '02 Daihatsu Rocky 'The Bully'

    "What can be asserted without evidence can also be dismissed without evidence."

  10. #148
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    Default Re: Prof's Rocky Thread

    Long time no post.

    The Bully going strong after the gearbox leak issues. It keeps putting a smile on my ugly mug and a dent in my purse.

    The Kitty sprung a headgasket leak....in November 2020. The previous owner had a timing belt break and bent three valves. Two years and 45 000km later slight leak. Came apparent after 1300km round trip to Hogsback. Pushes bubbles into radiator and then out the overflow bottle. Looses about a litre of water every 300km.

    Nursed it till now, actually drove it for approx 5 000km like that and watching water levels. Took it to 300 000km and time to save for repair. Wanted to have turbo, injectors & diesel pump checked. Headgasket kit (bought as it was available, now has to come from UK), timing belt, tensioners and belts I had lined up for 300 000km service already.

    Stripped all and there was leak at no 1 piston to water port. Barely discernible. Sent all away....Diesel pump was just normal maintenance service. Injector tips were 'fooked' (Diesel place's words) and turbo had play on shaft.
    Pistons look fine and not a large ridge to mention. Wasn't using oil.

    Diesel pump R4 313
    Injectors R3 197
    Turbo R8 625 (had to replace bushes, shaft ,vanes & actuator)
    Total R16 135

    Son came to visit for strip and coming tomorrow for assembly. His first large engine job.

    So all lined up for tomorrow.
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    '98 Daihatsu Rocky 'The Kitty'
    '02 Daihatsu Rocky 'The Bully'

    "What can be asserted without evidence can also be dismissed without evidence."

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  12. #149
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    Default Re: Prof's Rocky Thread

    Work done.
    Pulls much better, definite improvement in power. A third gear long hill can now be done in fifth.

    Going to Diiesel Pump shop tomorrow morning for precise calibration of diesel pump fitment.

    Put a R16 000 smile on the wifes face

    Attached Images Attached Images  
    '98 Daihatsu Rocky 'The Kitty'
    '02 Daihatsu Rocky 'The Bully'

    "What can be asserted without evidence can also be dismissed without evidence."

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  14. #150
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    Default Re: Prof's Rocky Thread

    Was it R4313 for the pump service only?


    Ouch nogal !
    Willem

    Ford Ranger 3.0Tdci Super Cab 4x4
    (workshop whore)


  15. #151
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    Default Re: Prof's Rocky Thread

    Quote Originally Posted by WAJ View Post
    Was it R4313 for the pump service only?


    Ouch nogal !
    First invoice is 5 Nov 2018 for 'The Bully', white one.

    Second invoice is for 3 May 2021 for 'The Kitty', blue one.

    Same work and price is consistent allowing 2.5 years between two
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    '98 Daihatsu Rocky 'The Kitty'
    '02 Daihatsu Rocky 'The Bully'

    "What can be asserted without evidence can also be dismissed without evidence."

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    WAJ

  17. #152
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    Default Re: Prof's Rocky Thread

    Prof

    I see that is says VE pump so am assuming its the bosch pump

    Thats a very good price

    Did they give you test measurements of pressure at all

    Mine on the 300 tdi is in need of some leak fixing and after 800 k am sure the pressures cant be in spec still

  18. #153
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    Default Re: Prof's Rocky Thread

    Quote Originally Posted by RossJ View Post
    Prof

    I see that is says VE pump so am assuming its the bosch pump

    Thats a very good price

    Did they give you test measurements of pressure at all

    Mine on the 300 tdi is in need of some leak fixing and after 800 k am sure the pressures cant be in spec still
    Correct on Bosch pump.

    Did not give measurements, but sure I can ask for them.
    Trust them to get all right.

    Idling spec for car is 650rpm, and after service & fitment precisely that on tachometer.
    '98 Daihatsu Rocky 'The Kitty'
    '02 Daihatsu Rocky 'The Bully'

    "What can be asserted without evidence can also be dismissed without evidence."

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