Split screen SUE

[SUE482]

On the rear quarter panels I decided to fit the trim in place and drill new holes for the self tapping screws, much easier than trying to locate the old ones.
[frame][/frame]

[SUE482]

Well all the difficult bit done in the interior now, back to the exterior. Rear wings, the ones I had have been in "storage" for the past 30 years so inevitabley the is a certain amount of rust.
Sanding, rust proofing, filling, priming, top coating and treating the underside with Stone Chip, with a final top coat to finish then ready to fit.
[frame][/frame][frame][/frame]
Fitted complete with beading, now ready for the rear lights.
[frame][/frame]

[SUE482]

Now I must admit there is some confusion on my part as to the style of rear light that should be fitted to the 1955 saloon model. Some of the pics I have seen show the rear lights with and without painted plinth, when I obtained this car in 1972 the lights that where fitted were "handed" and without a plinth. So its without a plinth I have chosen.
These lights are wired up incorrectly by the manufacturer, the RED and GREEN/PURPLE should be reversed as the brake lights come on when the side lights should be on. There was also no earth wire on this fitting, it relied on a good ground from the securing bolts which I was not happy with. So I drilled out one of the two pop rivets which held the bulb bracket on to the base and fitted an earth, sorry its BLACK/RED I didn’t have black.[frame][/frame]
Anyway here is what it looks like, I’m happy but I must trim that gasket. [frame][/frame]

[ASL642]

I think they originally had the self coloured mazac plinth (we have a '56)

Coming along fast now!

[SUE482]

On further investigation, yes I do believe you are right ASL642 thanks for the info. Perhaps I'll change them at some stage if I can locate a couple of plinths.

[SUE482]

While I'm waiting for the front and rear valances to arrive I had a look at the gearbox, I could'nt remember any problems that were experienced when the car was running but for peace of mind I had better have a good look at it. Here it is [frame][/frame]
and the inside, not too much oil about.
[frame][/frame]
Time for a clean up, Gunk it and presure spray.
[frame][/frame][frame][/frame]
That makes it a bit easier to work on

[SUE482]

Sorry if you find this boring but I felt it might help someone sometime.
On the extension casing I decided to renew the oil seal and bush that the sleeve on the prop shaft fits into as it was quite worn. After removing the end oil seal I could see what I was up against. It was difficult to get anything in the other end to drive it out with. I spent ages on this site trying to find if anyone had been successful and how, all to no avail. No doubt someone will tell me where it is.
This is why its difficult, there is a narrow hole where the 3rd motion shaft passes through and its impossible to get any force on the bush, this is taken from the prop shaft end with the bush already removed.
[frame][/frame]
The only way I could see out of this was to feed something in from the seal end and locate it under the bush and drive it out from the other end. I came up with this, the bush is out here of course
[frame][/frame]
I used length of 12mm threaded rod with a nut on the end as a driver, the widget could be slid in from the seal side and located on the bush which could then be driven out as shown
[frame][/frame]
[frame][/frame]
Measurements for the widget are 1.1" across the flats and 1.3" across the diameter all made of 1/8" material.
Inserting a new one should be easy, simple

[fiona]

I am so impressed with your dedication ~ I am doing my car bit by bit but unfortunately I have to use a garage to do the work ~ the Haynes manual and I had a quick parting of the ways lol ~ good luck and it is intersesting to see how you are going

[SUE482]

Thanks Fiona, is that the car?
Yes the Haynes manual is OK up to point, the Workshop Manual is even better, but by far the best advice is available on this Forum, tips and tricks complete with phots in most instances. That is why I like to keep a photographic record of every thing I do, before, during and after. Good luck with your project.

[irmscher]

Great reading and very interesting

[SUE482]

Thanks irmscher glad you find it interesting, I sometimes wonder if I go into to much detail, but then if there's not enough its even worse. So

[George Smathers]

Very clever. I like the detail.

George

[SUE482]

Well I spoke to soon, simple eh! the new bush at the end of the gearbox extension does not fit, I have had the extension in the oven and the bush in the freezer but there is no way that it will fit it is just too big. The prop shaft sleeve also does not fit into the bush.
All the suppliers have the same bush for the 803/948/1098 gearboxes, does anyone know if there is a difference because to make it fit would require increasing the gap so it will compress further and then reamer it out for the sleeve to fit.
On the 803 gearbox there is a rubber mounting, the new one will also not fit into the retainer again too large too wide and hole diameter too small to fit over the extension piece.
[frame][/frame]
Not much progress in the past couple of days will get in touch with the suppliers and get their thoughts.

[SUE482]

While I'm trying to sort my gearbox problem I decided to finish the rear of the car and fit the valance which I had previously sprayed and the bumper bar which I had cleaned and painted. Here are all the components except the bumper.[frame][/frame]
And fitted to the car. [frame][/frame]
Well at least its taken my mind of the gearbox

[SUE482]

Having read various threads which appear to suggest that oil may leak into the speedo cable eventually finding its way into the head giving false readings if the oil seal is worn, I decided to replace the oil seal. Here I have partially extracted the retaining clip from the brass body. I understand early versions were nylon but were later superseded by the brass type.
[frame][/frame]
Like the prop shaft bush it required some thought. I came up with this for removing the retaining clip.
Push a half round file into the clip making sure one edge locates in the split and turn while gently pulling out.
[frame][/frame]
This then reveals the oil seal the extraction of which involved gently drilling with a 13mm drill, the remaining metal cover can then easily be removed. It looks like someone has had a go with a screwdriver at some time.
[frame][/frame]
Replacement procedure is the standard procedure of putting the bronze casing into the oven and the seal into the freezer for a couple of hours, spead the seal in oil and then just press the new seal home, finally replace the retaining clip.
Another job done.

[SUE482]

Finally had a reply from suppliers regarding unsuitable gearbox parts they were less than helpful.
They maintain that its is the same end bush in the extension piece as for all gearboxes and this was verified by their gearbox engineer. Indeed a more learned gentry, an independent, than myself informed me that the manufactures parts list says the same as well. Well they are not, if the bush supplied were to be forced into the housing it would split. They are therefore wrong or they have been manufactured incorrectly.
Regarding the end rubber mounting they recommended that I cut it down to size. Great solution.
Both parts are not suitable for an 803 gearbox so beware they are 8G208 and MNT160.
I managed to locate a scrap gearbox and fortunately the bush and rubber was in a much better condition that the one I had, I also replaced the clutch leaver bush and clutch bearings while I had the the gearbox on the bench, and all the various bits of rubber boots etc. All other aspects tested out OK.
End result now finished.
[frame][/frame][frame][/frame]

[Robbiet9999]

Keep up the good work. would love to restore henrietta but havent time or room also as she is my everyday car would hate to spend all that time and effort then have some numpty open his door on her. also we are looking into adoption so the funds wont be there

[SUE482]

When I originally bought the car the engine had been replaced and was a Gold Seal this gradually deteriorated over the next couple of years, it was clocking up regularly 60 miles a day. I replaced it with this 10MA version some years later from a pick up or van, so it was all running OK up to when I took it off the road some 30 odd years ago. As you can see its been collecting rust and dust.[frame][/frame][frame][/frame][frame][/frame]
Just a bit of superficial work to do
What will I find inside I wondered, will there be any shocks. First remove all the external bits and pieces
[frame][/frame]
Remove the head and the rocker assembly, dismantle, clean and check for wear. This is what I found, Oh dear new shaft at the very least.
[frame][/frame]
Happy me, surprisingly very very little wear on the rocker bushes, valve and push rod faces so only a new shaft is required. Bushes on this version of rocker are not replaceable I'm told and if they were they would be required to be reamed.
[frame][/frame]
Looks a bit better now, you will notice that the oil feed to the shaft is in the first mounting, I understand on later engines it was in the second so always check the head.
I began to wonder what had caused the sever wear on the shaft and was it normal, then on closer inspection I noticed this, could this have been the problem? You can see that the oil way from the head has not lined up with the the feed to the shaft very well so I opened it up a little to give an easier flow path and made sure the oilways were clear using the air line, I wonder what the tolerances were for this and has anyone else experienced this problem?
[frame][/frame]

[MarkyB]

I'd expect the tree holes to be in line at least!
Friday afternoon head I guess.

[SUE482]

Yes Marky you could be right, in those days it was rife , so I'm told
I might still open it up a bit more yet just to be on the safe side.
Now the head was off I could inspect the bores, you can see that there are lips to each cylinder and on measurement it varied between 2-10 thou so a re-bore was deemed necessary.
[frame][/frame]
Now for the crank, the mains were oval by as much as 3 thou and although there was less on the big ends there was some scoring so a re-grind it was going to be, it can't get any worse.
These are main shells and thrust washers. The other half of the thrust washers are not shown here, I forgot. Please note the face with the grove runs on the face of the crank
[frame][/frame]
And the crank, con rods and big ends.
[frame][/frame]
Out came the camshaft, followers, oil pump and distributor drive. (See camshaft woes in mechanical) The camshaft and distributor drive were terribly worn and would require replacement.
Thanks must go to bmcecosse for pointing me in the right direction for the mini camshaft and oil pump, thanks Roy.