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Saturday 20 February 2010

Time to Split the Engine and Gearbox

This morning, I decided it was time to split the engine and gearbox. In the summer I noticed a oil leak from the drain hole located beneath gearbox bell-housing.

This leak indicating that either the crankshaft rear seal and or the gearbox input shaft seal needed replacing.

As I don't have access to an engine hoist, I decided that I would leave the engine attached to the front axle and once split from the gearbox 'wheel' the engine forward using the front wheels and a trolley jack under the sump for support.

As the engine weights approximately 150 lbs and the thought of it dropping on my toes wasn't part of my plan. I took the precaution of using a ratchet strap around the engine and trolley jack to ensure the engine remained centred on the jack and wedging the engine against the front axle using wooden wedges to prevent the engine 'spinning' once disconnected from the gearbox (see photo below).

Having removed both track rods this left both the front wheels free to turn independently. Fearing this would cause a problem when moving the engine I took the additional precaution of attaching a piece of timber between the front ball joint mountings in order to ensure both wheels would remain parallel to each other. The timber can just be seen in the next photo at the front of the engine. Finally both radius arms were released from there gearbox mountings and splayed outwards slightly to clear the bell housing.

With all the engine/gearbox bolts removed but for two, I was ready to proceed. Slackening both bolts so that I had about a 10mm gap between the bolt head and the engine. I then called on the trusty foot of Geoff to push the clutch pedal down in order to 'break' the engine and gearbox joint.

The big moment ! unfortunately, nothing happened. A second go, still no luck. "Perhaps if we depress the clutch pedal instead of the brake ?" offered Geoff.


Two seconds later, and pressing the correct pedal this time, resulted in a satisfying 'Pop' as the engine moved away from the gearbox by 10mm . Totally removing both bolts and the engine was now free to be moved forward as seen in the photo opposite. The red ratchet strap around the engine and jack can also be seen in this photo.

Success a split engine and gearbox ! and surprisingly secure.

With the two parts now separated I could examine the clutch and investigate the oil leak. My first observations was of a worn thrust bearing and also badly worn fingers on the clutch pressure plate. In the photo to the left you can see where the front surface of the top finger has completely worn through !

The the pressure plate will therefore need replacing and a new friction plate. 150 quid of unwanted expense.

Now to identify the oil leak, having remove the clutch and flywheel there is plenty of oil on the engine casing. New seal definitely needed. Interestingly, the bottom crankshaft seal retaining plate has a bolt missing (see photo below). Further evidence of previous 'tamperings'

The pilot bearing in the flywheel is also knacked so I'm looking at the following parts;

Crankshaft seal, pilot bearing, flywheel locking plates, friction plate, pressure plate, thrust bearing and a gearbox input shaft seal.

Enough excitement for one day !

Tuesday 9 February 2010

Head Work

With the cylinder head removed I've started the engine rebuild process. First has been the process of removing the valves in order to regrind the valve seats (thanks Al for the compression tool). I've also cleaned and primed the external surfaces of the head ready for its top coat. Below is a picture of the head during the process of refitting the valves.


Whilst cleaning the head, I also came across a date plate mounted on the exhaust/inlet top face of the head. I can only assume this is the date of the head manufacture or head assembly. The date is 21.8.54. According to the FoFH club, Tillie rolled off the production line on the 24th Sept 1954. The date on the head of the 21st August 1954 is therefore consistent with the manufacture of components prior to full assemble. A case of conception followed by birth. I must say, little discoveries like this are one of the unexpected pleasures of this restoration project. Its like being some form of industrial archaecologist. Pictured below is date plate.

Finally, last week was my Birthday. I'm pleased to say that Tillie wasn't forgotten. She benefited from a new seat (thanks to the Taylor's & the Chaffinches) and a new steering wheel (thanks Doreen). The next job is to split the engine and gearbox. Keep tuned!