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 XD Drive-line Rebuild

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Joshy351
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PostSubject: XD Drive-line Rebuild   Tue Jan 14, 2014 12:36 pm

So I finally got a bit of time to make a thread on my new project!  I'm rebuilding my XD Falcon's Drive-line including Engine, Gearbox and differential.  Here are some pics of the steps I have taken so far!
 
First up I ripped out the old single Rail Gearbox.  What a mess it is! oil everywhere even leaving a hand print as I got up out from under the car!
 
[img=http://illiweb.com/fa/pbucket.gif]
 
I made sure the new tail shaft I'm getting cut down fits into the back of this box.
 
[img=http://illiweb.com/fa/pbucket.gif]
 
Now I have everything disconnected and undone and she is ready to be lifted out!
 
[img=http://illiweb.com/fa/pbucket.gif]
Now moving the beast into the middle of the shed for more room!
[img=http://memberfiles.freewebs.com/76/18/85781876/photos/Rebuilding-Marduk-2014/DSCN0303.jpg]


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PostSubject: Re: XD Drive-line Rebuild   Tue Jan 14, 2014 12:52 pm

Up Up UP!



And Away!



And now bolted to my new engine stand!  Kinda looks pretty for a motor that needs a rebuild Smile



Now I got the extractors removed, clutch master cylinder and battery holder removed!



Now I removed the brake booster and the steering box!  It will be sent of for refurbishment as well.


I also got stuck into sanding up some of the bad paint and scratches, especially where the old clutch master cylinder leaked!




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PostSubject: Re: XD Drive-line Rebuild   Tue Jan 14, 2014 1:01 pm

Me and the missus got underneath and scrub the whole under body! What a sh1t job hahah!


Getting ready to under-body Respray!


Underneath redone with body deadner!  Looks brand new Smile




Second coat!



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PostSubject: Re: XD Drive-line Rebuild   Tue Jan 14, 2014 1:08 pm

now for the engine bay respray!  Came up a treat.  Can't wait to clear coat it!  Smile





I will add more pics.  Coming soon!


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PostSubject: Re: XD Drive-line Rebuild   Tue Jan 28, 2014 1:40 pm

I thought I would add some more pics of our progress!

I got Mel to paint strip some parts!



This is the diff I'm going to run! 28 spline from a EL station wagon!



Mel also etched primed some parts as well



And I stripped the diff down!



Got it to bare metal!


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PostSubject: Re: XD Drive-line Rebuild   Tue Jan 28, 2014 1:49 pm

Battery holder getting stripped!



diff looking good now!



diff etched primed!



battery holder parts primed!





Parts painted in desert rose metallic!

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PostSubject: Re: XD Drive-line Rebuild   Mon Feb 03, 2014 12:28 pm

Ok time for an update!

I got the sway bar painted!



Welded on the sway bar brackets!


Pulled the calipers out of the acid and rebuilt them!



And my mini spool arrived!



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PostSubject: Re: XD Drive-line Rebuild   Mon Feb 03, 2014 12:39 pm

Stripped back more parts.  Here are the backing plates for the diff!


rear cross member!



now for the mini spool insertion.  We were also going to lower the ratio from a 3.23:1 to 3.45:1 but there was something wrong with the pinion so we went back to the 2.23.



Also cut of the old wheel bearing and replaced them while the diff is apart.



parts and tools everywhere lol!



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PostSubject: Re: XD Drive-line Rebuild   Mon Feb 03, 2014 12:44 pm

finally got the diff finished and got it painted in gloss black 2pac.





other parts painted in the same black!







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PostSubject: Re: XD Drive-line Rebuild   Mon Feb 03, 2014 12:47 pm

more parts painted!








and the grill!



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PostSubject: Re: XD Drive-line Rebuild   Mon Feb 03, 2014 12:51 pm

My rear slotted brake rotors and pad arrived today!  Sweet!!



Mel on the job fitting up the backing plates!



Rotors and calipers fitted.  Looks sweet as!



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PostSubject: Re: XD Drive-line Rebuild   Mon Feb 24, 2014 11:51 am

Here is a bit of an update!


Diff is ready to sot in!





Cleaned up the shackle plates and I found a GT stamped in there, I wonder why they did that.



Clean and painted body deadner where the diff sits!



Painted up the springs!



more parts painted black.  My weight bench seconds as a paint rack lol.

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PostSubject: Re: XD Drive-line Rebuild   Mon Feb 24, 2014 12:16 pm

Sway bar mounts painted sliver!



And the diff is in and looks great!











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PostSubject: Re: XD Drive-line Rebuild   Mon Feb 24, 2014 12:31 pm

Now with the Diff and rear and new rear brakes on its time to start the tear down of the clevo!





With the heads off I started to strip down the bottom end!







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PostSubject: Re: XD Drive-line Rebuild   Mon Feb 24, 2014 12:36 pm

Crank shaft is out!  I haven't seen that 4MAB Crank in almost 11 years!




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PostSubject: Re: XD Drive-line Rebuild   Mon Feb 24, 2014 12:44 pm

Wicked my big brake upgrade arrived today! SICK!











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PostSubject: Re: XD Drive-line Rebuild   Tue Apr 01, 2014 1:24 pm

I got some more parts today!  Engine parts! The best parts Smile










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PostSubject: Re: XD Drive-line Rebuild   Tue Apr 01, 2014 1:28 pm







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PostSubject: Re: XD Drive-line Rebuild   Tue Apr 01, 2014 1:48 pm

I also got a new high volume sump the other week too!





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PostSubject: Re: XD Drive-line Rebuild   Tue Apr 01, 2014 1:53 pm

I also got the new front brakes installed!



They really fill out them wheels!



I got the engine bay clear coated!





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PostSubject: Re: XD Drive-line Rebuild   Tue Apr 01, 2014 1:59 pm

Power steering box fully reconditioned!





Also I took the block and other engine parts to my engineer in my Laser!





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PostSubject: Re: XD Drive-line Rebuild   Tue Apr 01, 2014 2:03 pm

All the new steering components bolted in!











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PostSubject: Re: XD Drive-line Rebuild   Tue Apr 01, 2014 2:11 pm

Gearbox fully rebuilt and painted!



Brake booster repainted!



More bits n pieces painted!



Wiring getting sorted and fitting out the engine bay!





A collection of stuff to be painted!




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PostSubject: Re: XD Drive-line Rebuild   Wed Apr 09, 2014 1:40 am

A quick update!  We found two bent Conrods so that slowed things a little but my uncle donated a couple of rods to me which was great of him. The block is bored and honed to 40 tho and I still have just on 2 mill on the bore walls. Just waiting for a new harmonic balancer now so we can get the bottom end balanced.
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PostSubject: Re: XD Drive-line Rebuild   Mon Apr 28, 2014 1:15 pm

Ok guys and girls its time for an update I think!  finally today we dummy assembled the engine and checked all the clearances.  I also filed back the ring gaps for the pistons too.  Now we just have to wait for my harmonic balancer to come back from PowerBond because I had to send it away because it slipped so we got them to sort it out.!

Here are some pics!

Here is my block after it was bored and now on the honing machine!




Fresh bores!



Here is one of those bent conrods!



Dummy Assembly!  Crank is in!



filing the ring gaps!



measuring the ring gap!  Sorry about the blurred pic!



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