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Workshop Tales Part 1 (long)



I am doing a major service on my 80 in preperation for taking the
family around Morocco in a couple of weeks.
I had toyed with doing some sort of blog of the work on the car etc,
but am short of time and wasn't really planning on taking the 80 so am
not going to bother.
However as I work on the car I thought I would post a few notes in case
they may be of some use to others here.
Anyway, yesterday Gareth Jones came down to assist with stripping down
the front axle to replace the CVs and all the seals and bearings in
Apart from some wear on the spindles the main cocern was the amount of
rust on the balls/cups at the end of the axle and also within the cup.
Most of the axles I have worked on have had a fair amount of rust on
the outside of the balls, but I have never seen that much rust inside
the cups and also at the top around the top steering knuckle bearing.
It was so bad on the passenger side that the cage for the knuckle
bearing had collapsed so Gareth ended up with a handdful of roller
I wasn't too surprised because at 150,000 miles the car has had a hard
life over the last three years and is usually run through a ford every
other weekend during the winter.
We sanded down the outer surface of the cups/balls and then treated
with Krust to seal any remaining rust - this should be enough because
the seals are only holding back grease and it's not under pressure.
One other note, avoid talking too much when assembling the knuckle
because you might end up trying to put it on the wrong way around or
forget to put the rear seals on before the knuckle.
I also showed Gareth the difference between the Milner inner axle seal
and Toyota one - when you have them sidde by side you can really see
the difference.
This morning I have been trying to remove the radiator to clean it out
and also give me a bit more space for removing the injector pump (going
to be serviced), changing the cam belt etc.
What a hassle, you have to remove the batteries, battery boxes,
indicators (to get to a bolt for the ...) headlights.
I'ts a bit belt and braces, but the last time I worked on an injection
pump I was forever skinning my knuckles on the radiator core.
Anyway I am glad I have because at the radiator core is caked in mud as
is the basically everywhere under the bonnet - I suspect from one of
the big mud pools down on Salisbury Plain.
An interesting thing, is that if you look at the front of the radiator
(well it's actually the core for the Air Con), it is pretty clean,
however having removed the fan and the cowling at the back I can see
that about 1/3rd of the core is completely clogged (and has been for at
least 12 months).
It hasn't caused any noticeable problems, but make me more aware of the
fact that you need to spend a lot more time hosing off the radiator
after playing in Mud.
One final point is that whilst I have loosely hosed off the engine
after the last Salisbury Plain, blowing off the cylinder head around
the injectors has thrown up a hell of a lot of mud - there are a lot of
nooks and crannies there where the mud can settle - I doubt it makes
much difference although in some cases this can effect the cooling on
the head.
That's all for now.
Next report will cover removing the injectors, checking the valve
clearances and then removing the injection pump.
Julian Voelcker
Mobile: 07971 540362
Skype: julianvoelcker
Cirencester, United Kingdom
1994 HDJ80, 2.5" OME Lift