As I started working on this car it was quite a steep learning curve for me, for the past 12 years or so all I had messed about with was front wheel drive cars and so my knowledge was limited when it came to rear wheel drive and 4x4. I knew all the basics in terms of how they worked and what everything did, but the mechanical detail I was lacking and so perhaps missed some bits earlier on that I really should have picked up on!
Needless to say it was all experiences that has given me a much better understanding of how this particular car has been built and what will improve it.
On to the photos.. So first up was to get the gearbox out to replace the release bearing which was making an awful noise! Gearbox out
And the noisy bearing - knackered!
Though on getting the box off I came across a host of other problems, first up I noticed that the rubber doughnut used as a coupling between the gearbox output shaft and prop shaft was knackered
So I knew this would need to be replaced.. Easy enough or so I thought. This is the older hexagonal type, the type fitted to the early Sapphire 4x4s.. So what it was doing on this car I don't know. It turns out that the propshaft was also the early Sapphire 4x4 item. The problem being you can not get this part for love nor money. They are simply not available anymore. Ford changed it for a different design in the later sapphires and for the escort cosworth. So I had to order the later one.. Problem solved.. For now.
I also noticed this but thought nothing of it at the time being told that it shouldn't cause an issue
This is the output shaft of the gearbox cut off to allow the early doughnut to fit, later this was going to cause me no end of issues!
Whilst the box was out and the starter had been removed I also noticed the breather drain pipe to the sump simply was not connected and therefore draining oil all over the side of the engine.. Another aspect to address.
The front UJ on the front propshaft was also knackered and had loads of play in it.. I've heard that this can fail whilst driving and take the diff, sump and a mass of other bits out so lucky I caught it whilst still attached
Old one out
New one ready to go in
Fitted
The gear lever frame also had some strange modifications.. I know what the aim was but to me this is not the way to stiffen the mounts onto the gearbox.. Welded washers over the original ford mounts..
So a set of poly bushes later (wanted some vibrations taken out as you can get solid aluminium mounts) and a quick test fit on to the gearbox
Whilst the box was out I decided to check the clutch, and I was dubious as to whether the rear crank seal was leaking so now was the time to change.. Good job I did. Had a snapped clutch bolt left in the flywheel so the clutch was only on with 5 bolts.. Great!
Someone knew this has happened when the clutch was fitted so why it was left is anyone's guess. So drilled it out.. Taped a new thread and fitted a helicoil. Nice new thread for the 6th bolt.
This was the suspect rear crank seal so out it came ready for a new one to be fitted
So new parts ordered.. By this stage I had noticed a leak in the gear selector shaft on the gearbox so got a new seal for that.. I had also realised that the sump was leaking.. So as I had the box out I thought now would be the time to replace.. Easy said than done!!!
