Wow, such a long time between updates. Havent done much in the way of modding but some intresting things have happened since last time. Starting off with what started as an oil leak.
And the story goes somthing like this:
Didn't do this on that trip, but about a month my last trip I discovered a small oil leak from around the gearbox drain plug. Lucky (or not as it turns out) for me I was at work so after id finnished the customer cars, I stuck the Surf up on the hoist and tightned up the plug, thinking it was loose. It turned a little bit then snapped off completely taking off a good sized chunk of the main gearbox caseing with it and vomited gearbox oil all over me. As it was midday on a saterday, there was nothing I could do about it so it had to stay at work for the weekend.
The following Monday:
Clocked off early to assess the damage and how to repair it. Determined a partial gearbox rebuild was needed. Removed gearbox. Had the great idea of replacing the clutch while the box was out. Encountered one of Toyotas greatest dumb ideas, the Dual Mass Flywheel.
Tuesday
Took the rest of the week off work to carry out nessessary repairs. Sourced a replacement clutch and Solid Flywheel Conversion kit from Exedy. Stripped down gearbox, found input shaft badly worn due to seized spigot bearing. Found transmission cross member and mount bent. Sourced replacement cross member and mount (genuine part ex sydney). Sourced 2nd gearbox to be plundered for parts. Clutch/Flywheel kit arrives same day, found out flywheel does not come with ring gear for the starter motor and that I have to re-use the original one. Spent the rest of the day grinding the plates and rivits off the old ring gear so I could heat it up and drop it on to the new flywheel.
Wednesday
Replaced rear main seal, spigot bearing and re-fitted new flywheel. Picked up "spare parts: gearbox from wreckers. Stripped down old box and took out parts I needed (input shaft, gearbox case). Cleaned up my box and put the input shaft in. Re-assembled completed box into the replacement case and re-assembled the rest of the transmission.
Thursday
Fitted new clutch (Exedy Heavy Duty) and put gearbox back in the car. Replaced clutch fluid and jobs done.
Friday
Driving to work, I found I had no pedal pressure on the clutch. Drove to work in 2nd gear. Found the slave cylinder had failed and was leaking. Replaced slave cylinder and re-bled clutch fluid. Now jobs done.
Total job bill: $1200 and a week off work