Up to my elbows in oil again. Mystery clonking. Diff Replacement.

[politeperson]

Evening all,

My S2 FHC started dropping gearbox oil after I refilled it with Red Line. It got to the stage when in the middle of last week, smoke was entering the inside of the car through the gear lever gaiter after dripping on the hot exhaust. Red line was definitely thinner than the old oil that came out.

Then to compound the issue i started feeling a wheel speed metallic knocking though the throttle pedal, and a clonk in reverse. Like a UJ.

I wanted to take the car to the Revival at Goodwood on Friday next week. Not looking good.

This morning I drove it around to my local secret expert Aston Martin and XK engine builder. He was finishing off a mini cooper engine to "k spec".

We jacked up the rear and he diagnosed excess diff backlash. He said it felt nasty.

I drove the car home, dropped the cage and removed the diff. I dropped it off at his place he will look at it tomorrow. It is a 3.51 LSD.

With the car in the air it allowed me a good look at the gearbox.

I removed the support, spring and cup which was full of gearbox oil. the prop was dry and I could detect no play at all in the UJs.

Gear oil was trickling down from way up then box. I put my hand up to the speedo angle drive and it was loose. I have tightened it so hopefully that has done it.

Whilst the cage is out I am going to to the wheel bearings and outer hub bearings. The inner fulcrum roller bearings look grotty, so ill do those as well.

Shocks springs other bushes are all new. Engine mounts, stabalise mount all new.
Wheels and spinners are new.

The outer uj is covered with a dust shroud. This has obviously been rubbing as it has a new ring marked around it.

Is is worth refitting? they all seem to grate and squeek. My car never gets wet so douse it matter?

The driveshaft UJs look good as well, I cannot detect any play!

Anything else I should look at before I put it all back together?

Anyone got a 3.07 I can bung in?

[politeperson]

Will this one do the job?


http://www.ebay.co.uk/itm/Jaguar-XJ6-4- ... Sw-itXuMIb

[politeperson]

Well,

I found some of the issues.

My secret engineer took the axle to bits. One of the bearing carrier bolts was loose! This was causing the race to spin.

Also, the "factory wired" axle to carrier brackets were both loose!

This allowed the axle to move around inside the carrier!

Looking at the wire, it looks like it has been loose for the best part of 50 years!

Bit weird.

Anyway, stuff the 3.51. I am picking up a locking 2.88 tomorrow from an XJS (Salisbury)> Hope my Girling callipers fit.

All the other Ujs, bearings and bushes seem excellent.

UJ outer dust covers have been deleted on the basis that they squeak like an old bed in a whore house.

Might get to the Revival afterall.

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[andrewh]

nice one. I will be seriously impressed if you can get this stripped, repaired, rebuilt and refitted within the time you have. Not impossible at all, just requires commitment and time. Good luck. You should be able to work out whether the callipers fit well before you fit the diff to the cage by just comparing the mounting flanges, which are interchangeable off the diff anyway as far as I know. See you on Friday hh-uh?

[politeperson]

Well that would be nice.

I will be in the Star and Garter in East Dean, hopefully, 7pm onwards. Come for a drink and something to eat.

I am really looking forward to Saturdays racing.

I am with a bunch of petrol-heads and we are staying at Mr Humphrys famous campsite, New House Farm

I will be in the Jag, a Red Tesla or a Gold Range Rover!

The gearbox leak turned out to be the speedo drive coming loose. Fixed (I hope).

So hopefully the Jag.

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[politeperson]

A quick update.

Today I picked up a Salisbury 2.88 LSD from Just XJS near Derby. Seems leak free and smooth with no grinding and no real back-lash.

All those in the know don't seem to rate the Dana unit.

After work I changed the rear finned alloy XJS cover for my e type one, I had a good measure up too.

The prop flange is correct and the output flanges are the same width, as is the brake mounts for e type calipers. So I can refit the e-type shims to maintain the camber, no problem. In theory.

I have fitted it into the e type cage, wired the bolts and swapped the lower XJS mounts for the E-type ones. Interestingly the wired-in XJS mounting bolts were only finger tight too in the XJS diff! Is this a Jaguar issue?

I refitted the half-shaft/hub/shock assemblies to the cage.

Fitting all those oil seal rings to the inner fulcrums is interesting. 8x inner spacers, 8x oil seals, 8x oil seal retaining rings, 8 spacer washers, all trying to fall out. Got the hang of it the second time around. Secret seems to be leave the lower cradle plate off until the arms are correctly assembled, otherwise it is all too tight.

Tomorrow, shims, discs, calipers, drive shafts, handbrake mechanism, shock upper bolts.

Then oil in, cradle up, cradle mounts shimmed and bolted, prop flange, hand brake, brake line connected, trailing arm bolts and safety bracket.

I found the easy way to fit the trailing arms into the cup is
1 Support the body.
2 Support the hub on a jack with the bleed nipple removed.
3 Drift out the lower shock arm,
4 Jack the hub assembly up into the body.
5 The lower trailing arm mounting point will now get closer to the cup, allowing it to just pop on so you can add the bolt.
6 Drop the hub, reattach the shocks-done.
Took me a while to figure that out last time.

Then, bleed brakes wheels on. Off we go. Maybe.

[politeperson]

Another quick update,

I got on it again at 5pm this evening.

Shims on, discs on drive shafts on, Calipers on.

Two of my caliper bolts were too long for the XJS diff for some reason. A couple of minutes later with the grinder, flat file and thread file and its all together.

Handbrake mechanism on. Grease nipples greased.

Diff filled with lsd EP90 (much easier to fill it before it is in lifted place I have found).

I wheeled it all under the car and it all went in first time.

I have found it helps if you leave the rear sub-frame mounts on the car, as the front sub-frame mounts on the cradle guide it all together as it is lifted. Literally took 10 minutes to align it and bolt it together.

Lifted the trailing arms up and bolted them through the safety brackets. Just like that.

Then it was 7.30pm and time to put small children to bed. Well, say goodnight anyway.

So it is in.

I still have to attach the shocks at the bottom, bolt the prop to the diff, connect the handbrake, reattach the brake line. I have a power bleed to get the air out.

So maybe tomorrow I can test my exciting new 2.88 diff.

[politeperson]

Well I got it all back together.

First thing I noticed was I had to slip the clutch a bit more and give it a few more revs to get it off the line.

All the gears seem to do something sensible. 4th at 3,000 rpm seems to be 83mph, so that is great.

Acceleration seems the same, the whole driving experience seems a lot less fussy, smoother and quieter.

The torque of the motor seems to overcome the new 2.88 diff easily.

Seems like I have paid a relatively small price to create a far better car.

Looks like I will be taking it to Chichester tomorrow.

I am very happy so far.

[politeperson]

Well we made to to the Revival, and it now goes like a rocket.

Met loads of e-type owners in the Jaguar Land Rover tent.

Excellent! bit wet.

Left Goodwood at 7.30am this morning, back in Boston 10.30am.

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[Bfastr]

WOW !!

thanks for the riveting yarn. I sat down with a cup of coffee and started from the top, I felt like I was right in there with you! very well done and I think I may have learned a few things too. I have an S2 with the 3.54 that I hate and the need to drop the IRS and tackle a few odds n ends while it is down. I may start looking for an alternate diff to try out based on your post.

would love to hear more about your thoughts on running with a 2.88 as time goes on.

[politeperson]

Thanks.

Its great with a 2.88.

I had to leave on Sunday morning, in this film I am leaving Petworth in my 2.88. Look at the cars coming in the other direction. The motor is spinning so slowly at speed, all you can hear is the wind. Not telling you how fast. Having said that I don't really know as I haven't had the speedo done yet!

I also have a film of me in the fast lane whippin' everyone.

I could win a film for the most boring film director in the world.

Maybe I will post some more films tomorrow.

Who is the owner if this S2. I had a sneaky peak and it looks like a Q car with Webbers.

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[288gto]

He is or was o member on here with a build thread...

http://www.myetype.co.uk/forum/viewtopic.php?f=8&t=5180

Edit. Forget that, different registration Nevertheless a similar car with lots of pics.

Simon

[Geoff Green]

Love the drive! Thanks for posting.