Pajero Gen 2 restoration

[mygoggie]

What happened? Did the Bossman fix the hole and the thread.

Spiceman, I will see next week what is what. Been busy finding bearings and parts. Three months of searching for bearings at everyone and his brother and then Bearing Agent replies within 24h with the correct bearings in stock. How is it that nobody wants to do business Managed to find a transfer chain and engine mountings from "Die Garage" - https://diegarage.co.za/

[mygoggie]

Bearings confirmed shipped this morning! Cool!

[Spiceman]

How did the white metal casting go?

[plunger]

How did the white metal casting go?

Me too wants to know. I would have just made one from phospher bronze, not oilite.

[MysteriousEngine]

Excellent news on bearings and chain.
Do please keep that locknut for me. Starting the job soon.

Regards

[mygoggie]

How did the white metal casting go?

Will try my hand at it tomorrow. I was waiting for a steel bush casing from uncle Brian.

Been replaying the process in my head a few times. I will take it slowly and make a video of my adventure.

[mygoggie]

Excellent news on bearings and chain.
Do please keep that locknut for me. Starting the job soon.

Regards

Will keep it and make your bush as well.

[mygoggie]

Me too wants to know. I would have just made one from phospher bronze, not oilite.

I investigated this route @plunger but phosphor bronze cannot handle 8000rpm ...

[mygoggie]

I started another thread about the white metal casting.

You can follow it here - https://www.4x4community.co.za/forum...or-restoration

[mygoggie]

I finally, finally, finally ... Oh did I mention, FINALLY found the correct bearings for the gearbox and received them this morning.

One Timken, one Koyo and two Nachi bearings. A bit of a mix and match but these are all quality bearings and I am not going to wait any longer.




Next step is to find my C-clip pliers which is somewhere in the garage ... always the very last place you can possibly look is the hiding place for these missing tools ...

[Spiceman]

You must be clever and start at the last place to look for them.

[mygoggie]

You must be clever and start at the last place to look for them.

Nou waarom het ek of Brain nog nooit aan dit so gedink nie ... ??

[MariusFourie]

Obvioisly it is always the last place you look. Who keeps looking after you found them?

[Racer-X]

Next step is to find my C-clip pliers which is somewhere in the garage ... always the very last place you can possibly look is the hiding place for these missing tools ...

i have an inner and outer set of cir clip pliers that you are welcome to borrow.

Yes, i have an ulterior motive:

I have a rear shaft vibration up to 2500 rpm in my V5M31

If you are successful i would like to copy your solution

[mygoggie]

The new transfer chain finally shipped this afternoon. Apparently the courier truck with the engine mountings was involved in an accident and a new set of engine mountings had to be shipped to Die Garage.

Times are getting fewer and it seems I can get cracking at assembling the drive train.

I have started to look at the last place and the C-clip pliers were not there. Nor at the second to last place or the third to last place. Tomorrow I will start at the first place. Do second and third and then alter between forth, forth from last, fifth, fifth from last until I find it. Hopefully in the Centre. ....

[mygoggie]

i have an inner and outer set of cir clip pliers that you are welcome to borrow.

Yes, i have an ulterior motive:

I have a rear shaft vibration up to 2500 rpm in my V5M31

If you are successful i would like to copy your solution

Thanks @Racer-X, but I have those pliers. The C-clip is something else ... Will take a picture in its hiding place once revealed!

Sounds like you are sitting with the same issues as I have. Sure, you try my solution as long as you take the mistakes with you!

[mygoggie]

And it was time to clean the garage .... spent the whole morning clearing two of the workbench tops so that I can start working on the gearbox.

And I found my C-clip pliers. Yes, it was in the first last place I looked. It fell in behind the screwdrivers in the screwdriver rack.

@Racer-X this is what it looks like.







The business end is flat with dimples to allow the C-clip end to grip in these dimples.







I then could remove the last C-clip on the last gearbox shaft. Do you spot the clip? I opened it and slid it back onto the shaft.







The shaft removed and ready to be cleaned.







As is the gearbox casing.






Shaft with gears was actually not that dirty and it washed clean very quickly with some paraffin.







Last wash with clean paraffin.






The gearbox casing washed with paraffin and then onto brushing the outside faces with a brass cup brush.






Pressure washed and clean of all dirt. Lots of surface rust is visible! Oh, what to do?!!






Easy peazy, just brush some phosphoric acid on and let it stand for a while.






The rust is almost removed. I coated it with another layer of fresh phosphoric acid to get rid of the last bit of rust.





I will do a another post hopefully this evening with the first layer of acid primer painted onto the external surfaces.

[mygoggie]

It started raining so I moved back into the garage with the gearbox casing.

Other side coated with phosphoric acid.






Almost all rust is gone. Time to coat it again and let it stand for a few hours.






Zoom ahead in our time traveling machine and here we are!

Ready for painting with etch primer.











All done and watching the paint dry ....






All areas dried and looking good!






Onto cleaning all the gasket surfaces of any etch primer.












Next step is to mask these gasket surfaces and get the casing ready for spray painting. Taped ...






And tape edge hammered and the surplus removed. Hammering with a ball peen hammer cuts the tape like a knife and gives a nice and clean edge.








The next face hammered.







And pulling away the overlay tape that we do not want.













And the last face taped, hammered and cleaned.






Tomorrow I will spray paint the surfaces and then onto assembling!

[EtienneB]

You are so brilliant in the detail Herman. Regtig!

[4eTouareg]

Respect!!!!

I think even Dave Kindig would be proud of you!