Finished Bitza!

[anothernz45]

Took the shiny one to the Caroline Bay Beach Hop, 1200 cars, brilliant weather and a very well run car show, big thanks to all the organisers for a great weekend.
Sundays events included a look through some local mancaves/car collections and one surprise was the 2 FJs.
Only issue I had was the transfer case starting to drip again, will speedi-sleeve and double seal this time round. Dynamat on the roof and the 31s made the trip a lot easier on us.

 

[anothernz45]

Advanced Upholstery in Darfield refitted the original headliner and trimmed the edges and corners so they don't trap moisture in the seam. This along with the Dynamat underneath has made driving a lot more civilised.
I've just built a bar along the front of the tray to attach a tonneau cover, that's the next project. The little Alfa in the workshop embarrassed itself last time I took it out - it hasn't had much love while I've been working on the FJ45s, lost all spark. New dizzy cap should sort it.
Duck season has come round again, the FJs been ferrying feed out to the pond and even got a run opening day - ended up with 9 mallards.

 

[anothernz45]

Tray bar all done, ready for paint. Upholsterer needed somewhere to put the clips that hold the front of the cover.

 

[anothernz45]

Thought I'd deal to the leaking transfer case - pulled the rear seal housing off another one and turned enough off it to fit a second seal, had to be 2 6mm wide seals, then removed my parking brake drum and found everything was nice and dry. Put that back together and fitted a new seal to the front output shaft, figuring oil must be coming out there and blowing back, I could see a streak of oil along the housing then running down the brake backing plate. Still dripping. Checked the 6 bolts round the casing holding the front dog clutch and output shaft - 2 of them were over a turn off being tight, the rest not snug either. Have just tightened them all and will see what happens, I may have to remove and seal the gasket but fingers crossed.
Another stuff up I made was putting a new pinion seal in the rear diff and tightening the nut back up, there was no backlash left and the diff is tight.
I made the same mistake with my 70 series 12 or so years ago, and have just had to fit another diff head, the front bearing is worn and then when you tighten the pinion nut you push the pinion back into the crown wheel. Have only put 6000 kms on the 45 since, the 70 lasted 120000 or so, will find the best 40 diff head I have and get that reconditioned then swap it in.

 

[anothernz45]

Tray cover made, thanks Brian and Sue, Advanced Upholstery.

 

[anothernz45]

Really mild winter over here, gave the 69 a bit of exercise - and me.

 

[anothernz45]

Not the 45, this was the PZJ77, shop fitted another rear diff head as mine was shot. The pinion shaft flange was different so they ended up using the flange off my original diff, everything seemed sweet then a small click appeared as I backed up. Looked for it, suspected worn shackles, shock mounts, rear overider, driveshaft - then it went away. About a month later I let the clutch out and there was a graunch and no forward movement - stuck my head underneath and let clutch out for a bit, driveshaft turned, wheels didn't. Trailered back to the shop - the old flange spline was now a round but hadn't stuffed the new(er) shaft. Are fitting a new Terrain Tamer multi fit flange. Moral here, check that spline and if you develop a click this could be it.

 

[anothernz45]

A bit more on the tight diff mystery - I fitted a new oil seal to the rear diff and torqued up to spec, and found the pinion shaft was tight to turn. Did the same to a 70 a long time ago. The new seal was different, it had a nose seal thing to keep rubbish away from the oil seal lips so I lubed everything up and hoped for the best. Anyway, it's still tight - was talking to a diff shop mechanic, he said that once there's a bit of wear in an old diff that's what happens - they need about 1 1/2 thou of shimming to bring them right, havn't looked into how I'll do this but will post when it happens - or give it to a shop.