DJ2.1 Rebuild

[maxstu]

I was gonna say
Yeah I was lucky and andrew had two pistons that measured the same as the ones that were decent on my engine

Was hoping AJ could shed some light on this issue. May well contact him directly asking his advice.

Meanwhile, what's the latest with your gearbox malarkey?

[Stesaw]

Not done anything yet waiting on a potentail AAP gearbox.

[Smiffo]

viewtopic.php?t=177170

This one?

[Stesaw]

Yep

[maxstu]

Good luck. 

Whereabouts is it?

[Smiffo]

Wait.... Don't you need a Syncro gearbox, Stesaw? 

[Stesaw]

Wait.... Don't you need a Syncro gearbox, Stesaw?

Yes and no.
I've made no progress on the syncro build other than getting the panels ready for the fuel tank and filler.
As I will be moving soonish I'll need the van with a gearbox that works to haul all our stuff.
I don't have a front diff/prop etc for the syncro so it's no rush. I do have a syncro gearbox but it's in bits due to a broken 3/4 hub.
I've toyed with the idea of rebuilding it, but I'll need some specific tools and a decent press, not to mention other bits for the box such as new bearings, to which I don't have the money for at the moment... although saying that if the bits are less than 700 quid it might not be a bad idea

[Smiffo]

I wasn't expecting an answer like that!

I know we said we wouldn't mention the Syncro.... But.... It was sat there begging me to be mentioned   

Good luck on the move though Stesaw. 
Some say the most stressful thing most people go through. That's debatable, but it's right up there in the top 10 



 

[Stesaw]

I wasn't expecting an answer like that!

I know we said we wouldn't mention the Syncro.... But.... It was sat there begging me to be mentioned   

Good luck on the move though Stesaw. 
Some say the most stressful thing most people go through. That's debatable, but it's right up there in the top 10 

Haha nah why get a 2wd box when I'm doing a syncro conversion it's a valid question and it makes perfect sense really.
If I knew I could rebuild that box for the same money I'd do it. But I doubt I could that and I'd rather change some gears as well as I'd prefer a better cruising speed.

[ajsimmo]

"What is weighed together? Piston, rod, pin and sleeve?"

Not the sleeve (I prefer barrel), just the reciprocating assembly of piston, pin and clips. Weigh the rods separately, then combine them for as close as possible to equal total mass on all. This is, of course, after selecting new rods, or replacement of stretch bolts in old rods.

Sent from my moto g(30) using Tapatalk

[maxstu]

Back on the engine rebuild after a bit of time out from the work shed.

Water closet attached to main bedroom given a quick redecorate and fitted a sink/ toilet combo. Maxine choice of wallpaper and colour. Apparently all the rage and in Town & Country magazine called "cocooning". Don't shoot the decorator!



Valve train taken apart today. Both shaft's showing wear on the bottom edge. Could not find an measurements in my manuals. Replace or just revolve each shaft 180 degrees?



Keep it all in order.





Cleaned and ready for assembly using assembly lube.



No 1 inlet rocker adjuster badly damaged. Will exchange out.

[Smiffo]

Thread resurrection time!! 

[maxstu]

Forgot about this.....yet mightily important for me to get some resssurance from the forum.

When the water pump gave way it damaged the case. But only internally. Is this a problem? About 2-3mm scoring.
The actual mounting face is undamaged

[ajsimmo]

If the opposite face of the shaft is in good nick, it's ok to rotate 180 to use the fresh thrust face. Any adjusters with pitting or mushrooming should be replaced.

Sent from my moto g(30) using Tapatalk

[maxstu]

Thank you. Both shafts are clean on the top side. So will rotate 180.

Rocker arms are without any noted side to side movement on the shaft. So they are good to reuse.

More cleaning...

On to the cases for a bit more cleaning and preparation. I used fine wet and dry paper with brake fluid to clean where barrels make contact with cases.



Bottom one cleaned. Top one next.



Every thread cleaned with a wire brush and an appropriate die run along it's length, including the head studs, which are all in excellent condition. Not a single rust blemish.



The head stud will be given a final wash over with neat alcohol to remove any lubricate or anti-corrosion fluid lve spray on everything.

The other case will get the same treatment tomorrow.