Paul Marx but you do understand it for the engine the gearbox they strong
our fingers into the part has been butchered we're at least have given you
a challenge its September 2019 and I'm in Cape Town about to rebuild a 20 year
old Land Cruiser I bought blind over the Internet
I've secured the services of Paul Marsh professional expedition vehicle builder
and new bear snowman Land Cruiser specialist extraordinaire that's got the
newest pick of berries we've been through the testing and diagnosis and
are about to begin disassembling major components in order to see what will be
needed to give this Land Cruiser 105 a new life well good morning one full day
has passed since I was last here drop the vehicle off course met Paul chatted
with you bear and if you have any watch it in the series this is basically my
build of my Africa Land Cruiser it's a 20 year old vehicle that's three hundred
thousand kilometers of work behind it and we are rebuilding it and preparing
an overland truck that I will be using for the channel for our exploration in
Africa now so now it's four-wheel drive our specialists at Land Cruisers as you
can see there are Land Cruisers as far as the eye can see and we have now
enough time has gone by for them to have actually stripped the vehicle down to
where they now can service all the parts and then start replacing it and we have
discovered a few things that were a little bit unexpected
I'm Andrew st. Pierre White join me as I share my passion for building four-wheel
drive trucks and traveling to the remotest parts of the world all right so
here we have all of the bits that you've taken or must remove out of the vehicle
now I'm going to ask Paul to help us understand where to find signs of wear
wear and again to tell the story of the vehicle and how to decide whether things
need replacing or can just go back and maybe if we don't have a limitless
budget go back and we know to keep an eye on them in the future at this point
we know that the gearbox has a major Fault in Reverse so it's been sent off
for a rebuild debauch secondly the transfer gearbox has been
investigated the presence of freewheel front hubs suggests something isn't
right there either the proper balance thought the chassis is in good order
really in good condition that's that's what I look the cooling system is a bit
of a mess and the aircon has been disconnected
but with the basic investigations complete Paul has decided that it's
actually a better idea to remove the engine altogether
that was a bit of a surprise to me so and we've taken your car your your
engine out the car it made a big difference because we had to change the
engine mounts because we had the gearbox or from the radiator out it just made
much more sense to pull the whole engine out with a little bit of work and it's
it's yeah in front of us I can just go through some of the things that we found
on the engine probably that I would look to check for
basically going back to telling us the story of what we found like yo le I said
the big oil leak that we found running down what looked like could have been
from the battery our main oil seal on the back of the engine which sits here
or possibly from the gearbox was actually just the Tabard cover okay
which is good news it's very good news but we're still going to change that
seal because we've already got everything out and it's such a short
change when you do a gearbox and we take the flywheel off when we send it to an
engineering firm of a machine the flywheel the high fat the new clutch and
that's saying people don't always do take a warden flywheel which possibly
even has eight spots on it in the worst case scenario sometimes that have cracks
from plate and you can see a blue discoloration on the flywheel so it's
always worth taking a flywheel off machine at darkness surface grinders
check their rear main oil seal and change it so if I may just go back a
little bit you decided to take the engine out because the gearbox was going
to come out because of the problem we had discovered would you have normally
taken the engine out in the vehicle like this and at what point would you say no
it's not worth taking the engine out given the fact that we have to do the
engine the the mounts gearbox Mouse as well so it's not necessary to take the
engine out in many cases because there's a lot of extra work a lot of extra cost
but in this scenario we are changing the radiator and we're changing the air
conditioning condenser so for my inspection we saw that both of those are
compromised and we've taken those out the gearbox is out and we're going to
change the gearbox the engine mountings and you'll see from one of the mountings
that you can see a signs of where a lot of that work can be done with the engine
in place it just can be left there it's much easier to not create extra work and
extra cost if you don't need to ok so you're you're saying that there is a
point where you realize that actually taking the engine out was actually going
to save money because it's now going to be easier working on the engine with it
out we're gonna save a little bit of money but the point is that you had to
make the call in the best interest of the project money being one of those
interest it has to be yeah that to take the motor out was
actually the best course of action because to be honest with you I walked
in here this morning and I looked and thought well it looks bad you've taken
you've literally dismantled the car so but you're saying actually at there's a
we reach the point where this was going to be a better option you know in when
you're trying to do work on the engine and change stuff and you're lying
underneath the car trying to change a seal and you're trying to do work on the
front this is going to be the best position where you know you can put
stuff back on the engine easily now you know you can do it all in city you
absolutely can if we weren't changing your engine mounts and we weren't taking
the radiator and the air conditioning condenser out the car engine would still
be in your car you probably would have been happy this morning
because I didn't tell you we're taking it out anyway so what we looked at here
course seals are a thing that we're a lot ok and when we're doing bits off the
front which is the timing belt now this engine runs with the timing of a timing
belt that's something which does get changed on regular service intervals but
winner redoing a truck for expedition I now don't know the history of the truck
I don't take any risks for that so I will put a complete timing belt kits and
terrain team have supplied us the complete kit with the with the idler
bearing with the actual seals we need for the camshaft but now it's important
before you just put new seals on that you see how worn is the dart and what
weird shafts so if I look at the shaft over
here as your camshaft here okay yeah there is slight wear here and if I take
my finger and I rub it along you can see there's this some shiny spots there
where the seals is run okay now it hasn't grooved it it's got a slight way
we'll take that and will will comfortably clean that up with a bit of
1200 water paper and it's like refacing it for the new seal to run like where we
did four clean that up nicely put the seal back
in a little bit of lubricant grease on there and it'll be perfect it will not
be a problem however but campaign there was a big groove in there deep groove
where you can imagine grease and dust mixing up creating grinding paste and I
see that that's worn that's gonna tell me if I put a new seal on there's a
chance it could leak again and we don't want that it's a part of going through
whatever we stripped off be it wheel bearings get stub axles is to examine
what we put in back and how good is part we're putting a seal on or the gasket on
so making sure the surface here is all true these tappet covers that come in
here it's a plastic tab it cover this engine gets really hot they can
sometimes warp and you know then you have an oil leak which is you put a new
gasket and it still leaks so it's again telling us the story
so we happy we're gonna put a new gasket we're gonna check the tappet cover to
make sure that it's nice and true and flat so when we put the new gas go on
tighten it down it's gonna seal it new seal on a can here you can see we've
removed the water pump inside here it's quite good actually normally you'd find
in if an engine it doesn't have a lot of antifreeze and the misconception for a
lot of people is antifreeze is there to lubricate the working parts inside the
cooling system like the water pump the seals and the water pump it also stops
corrosion and it's really really important that people don't actually put
enough antifreeze or change it often enough and depending on the coldness of
the climate you're going into will vary the ratio of how much antifreeze you're
putting into a system the cooling system so I want to make sure that every time I
look in my cooling system I can see there's antifreeze you can measure it
you could get a lot of ways of checking the concentration of antifreeze so I I
check it looking at the color of the it must not be clear it must be either blue
or orange the concentration is what fear is okay so I normally mix a 50-50 mix
and need pure glycol antifreeze from turret or a really good quality make
I'll mix it with distilled water and I'll put it into the cooling system okay
and I'll make sure the overflow bottle also has some antifreeze in there's
still water I use distilled water you know my tap water look you can if you
have to but remember that's all got properties in the water to store there's
more pure it's not wrong it's just one of the things I like to do okay so I'm
taking the water pump off we're changing it your water pump wasn't leaking and
I'm going to show you the word pump just now there is a tell tale of the water
pump leaks but it's one of the things that this water pump fails you really
can't drive the bar with the water pump that's leaking because you're
compromising the cooling system in a big way so that's one of the parts we always
carry spare and it's not the old one we've just taken off because that
eventually dries out the seal where the seal that's been worn bits of rust
collect and you're putting old one back on and very soon as seeking again so
I'll carry another new water pump maybe not even the same quality if I need to
save a bit of money but as long as it's a spare which is can we can take with us
the best one and the best quality one is going on water here we've taken the
crank off
so the big crane pulley that sits over here let's come off your timing belt
sets yeah and you'll see it when it all goes back on with a new timing belt and
the tension and all that here again the text I want to make sure that this
actually feels good this is well there's nothing wrong here you can feel that
that's lovely it's nice and smooth perfect so when we put in your seal on
there yes that's not going to give us give us any problems at all where it
says for the wrists you know we changing the past during the past during pump
we've taken orphan and that's going to be change Lee we've looked at the rest
of the motor it's in really good condition and we know from the records
that you and I looked at that this motor has been opened it has had work done on
it so I'm confident it when I put it back together with new with the new
injectors with new little plugs with all the accessories we're putting back on
this car is going to last a long time and give you a lot of many miles of good
driver good well that's that's good to know
so we've taken the diffs out okay the big thing is we've had to strip down the
axles we've taken Assad shaft out we want to actually check the condition of
the disks with the diff in the axle you can check for backlash you can actually
check that the amount of movement on the front flange here to what degree it
moves backwards and forwards compared to the movement inside here on the crown
wheel and the pinion so the biggest challenge you have is once you start
getting a lot of play between the teeth here and the inside here if you look in
here you've got your pinion your crown wheel here and where these teeth mesh
you get play and to set up the difficulty with the bearings that are
sitting carrying the actual triangle opinion it's important that all this are
set up in tolerance and as a where happens and as people driving and over
the years of wear and tear the bearings where the teeth can wear and the
distances between the teeth can also start increasing and that's when you get
play on the difícil backlash on it off so by taking the dips out we're giving
ourselves a confidences we could actually visually look at these teeth we
can look at the wave patterns on the teeth we can look at the coloration
we're looking for problems is there tooth that's chipped or broken
there's no distinctive wear patterns and you'll see you wave patterns on there on
the crown wheel when it starts a lot shinier and you can see it's almost the
teeth are quite worn and sometimes even rounded edges so in this particular
instance I'm not even gonna strip these disks the bearings feel good we could
strip them down we could put new bearings in but the condition is telling
me actually I'm prepared to take the chance on these because there are such
good condition looking at the actual teeth and everything that's worth taking
a chance on if we found that there was a lot of play here the seal was leaking we
could say okay look let's change all this let's strip them down let's do the
seals let's do everything so here's where you've got to make a call because
it has been way okay on these discs but because we haven't got any potential
problems on them let them be the worst case scenario is that at some stage you
might find a seal starts leaking here okay it's not a difficult job to change
that you don't have to take the older part you can change the seal but for the
sake of what we're trying to balance the project out in what we spend and what we
do we're not trying to rebuild a car in its entirety we're trying to basically
take this vehicle and put it back to a very good condition on the road which is
gonna be safe reliable and give really good miles on overnight
the drive shafts are a different story we've taken those out to be replacing
the front drive shots and those do take a lot more ways so these come up we
clean them up we check everything put in your gasket on clean the inside of the
of the diff housings properly so that we can take any sludge or any metal
particles that are lying in the diff that you don't always get to so it's
important to wash the difficut out properly before we put this back in so
when we put the new oil in it's now in a nice clean environment and it actually
works and actually prolongs your life you know oils are their lifeblood it's
like the blood in our veins it's the lifeblood of us it's the lifeblood of a
car so of course oils are not expensive good
quality oils are essential and change them often so looking closely at these
hubs and bearings is just taking me back to my my Range Rover the last time I did
this kind of work was with a vehicle that was also close to 20 years old it
didn't have close to this mileage on it and I ran bearings and replaced hubs and
hub seals and all this kind of thing says there's a certain there's a bit of
I'm starting to remember things that I haven't had to deal with in a very long
time the used parts table will slowly fill as
our new parts table empties I'm looking forward to how this'll look in a few
days time sure so they have supplied us with a belt pit
yeah it's really nice the way they do it because the bags are really useful for
one I really like these that go into my spares kit and what happens with belts
and as you find it belts get hard and they and they do they
do sometimes crack if you had to look in there you'd often see that you get
cracks appearing and in the builders that melt is actually really quite tired
but I found with belts is that in the ambient temperature is really hot in our
climates in Africa it's dusty it's really hot under bonnet temperatures are
hotter belts actually shorten their lifespan and people look at a belt in
they'll say well they look alright they're not pretty much frayed up so now
what happens is the people will win the belt slips and you Herot when you start
the car the tendency is just to adjust the alternator or the aircon tensioner
and all that does is just put more way on the bearings the belts not gripping
because it's hard and it's tired and it's all it's much better to take a new
set of belts and actually they're softer you can feel a little bit more grippy
put the belt on and the best way to test the belt between the two pulleys is to
just once you've tensioned it up trying twisted 90 degrees you shouldn't get rid
of it watch past 90 degrees over tensioning a
belt does more harm than under tensioning it so you don't want a belt
to slip but you don't want it too tight because that actually puts a lot of
premature wear on on bearings in the alternator and air conditioning so I
always change belts I always carry a spare set to belt the old ones are fine
they're not completely finished at first but they won't carry them especially
yesterday so they're because I actually ran a number of belts on my 105 and I
which had spare so we're gonna hold onto a nice set of spares for and as you I
think you mentioned to me you had a problem because the the pitch of the
belt wasn't correct which was yes was a it was a pirate part
even though it was labeled Toyota turned out to be a pirate part and the profile
and the East come in a matched pair writer do okay so there was a matched
pair wrong profile and they just started breaking over a very very short time so
I learned something about that too while they're busy doing that it's a it's a
slightly over slightly overwhelming I'm just so glad these guys are just taking
it and just obviously know exactly what they're doing as well because I am kind
of
a lot more is being done to the vehicle than I thought would need to be done is
this typical
probably that's what I will do is during the process of making these videos I'm
going to come up with a we're going to come up with the costumes in other words
realistically not every part here is needed for this vehicle they're not all
masks you must replace all of these parts that's not the case nor several of
these parts we don't really need to replacement terrain tamer giving us the
parts we're obviously going to replace them but at the end of it I want to be
able to present a if this was a typical vehicle what components must be replaced
what components yeah we could get away with it or others no don't need to
replace them at all to give you an idea realistically speaking what can be
expected when buying a vehicle with fairly high mileage and converting it
into a really reliable truck with another 150,000 200,000 300,000
kilometers back into it