So massive job half completed this week.
Mrs Sharpey is off in Cape Verde this week celebrating her 30th year with her girly maates. That meant i could take a week off to work on the Zed!!!
So starting Wednesday (i ended up working Monday and Tuesday) i started the process of rebuilding the rear end of the car.
Before i started this jjob i made sure i took all the advice i could, thank you massively to
@Lee and
@GazHyde for great advice
Parts sourced
Revshift rear bushes with 12mm+ diff raising kit
Powerflex rear trailing arm bushes
Pagid brake wear sensor (mines missing)
Pagid handbrake cables
the process as i did it.
jack the car up the day before and Plusgas everything you can see .... especially if your car spent it's life on the coast like mine
Jack up the car and support on 4 x axle stands, making sure the car is as level as can be (my driveway is like the surface of the moon so quite tricky)
unclip all the electrical connectors
2 x ABS
1 x brake pad wear
1 x speedo in the diff
undo the exhaust, luckily being a pre face lift 2.8 my exhaust unbolts in the mid pipe after the cat
undo the 4 x 16mm nuts on the propshaft by the diff (bag the nuts) also mark the position of the diff so you can put it all back the same way
undo the brake calipers and carriers, remove the discs and handbrake shoes, DONT drop the small pin that holds the handbrake cable in place
undo the rear droplinks and push out of the way
undo the rear brake line flexi's near the rear arms, block the pipes or put bags on them
this bit was a pain, make sure you use proper flare spanners otherwise you WILL round off the unions
make sure to bag everything up and label as you go
at this point go get some paracetamol as you will have continuously whacked yourself against the extremely hard metal diff cover
go have a cuppa and some lunch, time to tackle the shittest part of this job. The horrible little b*****d 6mm bolts holding the support bracket on
best thing about these are: they are full of crud, a pain to get to (especially the drivers side) and if these don't come off the job is ballsed
take your 6mm 3/4 drive bit and hammer it into the bolt so it is well and truly seated, give a small prayer to the car gods, and unwind. they aren't very tight but they are a pain.
mine all came out without too much difficulty
grab the ends of the hanbrake cables in the hubs with some mole grips and just wiggle and pull and mine popped out.
undo the nuts on the lever end in the car and pull the remainder out when the beam is removed.
undo the lower shock mounts
support the diff / subframe on your epic new hulk themed jack
undo diff bolt
undo the large nuts holding the beam on
lower and wiggle / wrestle it out
drag it into your garage, clean up and call that day 1