IRS Rebuild

[colinevans]

Morning all
Question re locking wire on rear S2 calipers. I assume that this applies to early S2 calipers that had the horseshoe brackets and not the later ones like mine that bolt directly to the diff casing? As I can’t see how you could put safety wire between the two mounting bolts because the line between them is interrupted by the casting on the diff casing?
Thanks, Colin.

[mgcjag]

Hi Colin.....you still wire them...difficult position to do it n and wire just bends around the casting.....Steve

[colinevans]

Okeydoke thanks Steve

[colinevans]

Evening all
The inner fulcrum brackets seem to require a fair bit of shimming to line up well enough with the cage to allow the dummy shaft to slide through without a fight. Is this normal? Alan Slawson took the brackets off for the diff refurb so I don’t know how many shims were there before, I guess the cage has twisted over the years. The diff to cage bolts are loose but there isn’t much give as all the weight is on it (I’m assembling upside down). I could put a jack under the diff and take the weight off the cage and see if It can line up a bit better, or just get or make a few more shims. Appreciate any advice.
Cheers, Colin

[mgcjag]

Hi Colin.....bolt the diff to the cage at the top.....turn the cage upside down.....you need to bolt the bottom plate to the cagd so its all in the correct shape......diff brackets on loose and slide in dummy shaft...then feelar guages to measure shims required......Steve

[colinevans]

Hi Steve
That’s exactly what I have done but my point was it seems to want a lot of shimming on one side. Is this normal and nothing to worry about?

[mgcjag]

Hi Colin.....all i can say is you shim as required..you do need to tighten the diff to cage bolts so the taper gets the diff in the correct position....do you have the correct brackets?..have they been altered in some way........has the cage been damaged repaired?......what gap are we talking about?......Steve

[colinevans]

Thanks for coming back to me Steve. Everything is as it came off, no replacements or repairs but as I said I don’t know what shims were there when Alan took them off. I think it will be around 35 thou on one side (assuming the 7 thou shims SNG sent are actually 7!) but prob only minimal on the other, which is what makes me think the cage has twisted a bit over the years.

[mgcjag]

Hi Colin...that dosnt sound like a problem. ......Steve

[colinevans]

Great thanks Steve

[Dal]

Big shout out to Steve Bitsobrits reply #22.
Upgrading the damper shaft to Series 3 is one of the best posts I’ve seen. The radius arms are always in the way and who wants to keep unfastening the hub shaft.

I reversed the radius arm bolt and shortened it by 8mm. The nut inside the wishbone needs to be cut down to the size of the bolt head and tack welded securely. Use series 3 tab washer bent over to keep it from backing out.
Thanks again Steve

[Dal]

Series 3 tab washer is c25401.