Dave's "S200KYS" Jimny 'laner Build...

Diff finally out at 7:30pm last night, would have started earlier if I'd known... it's much easier on a Vitara as the bearing retaining plates are seperate to the brake backing plate and can be eased through the centre of the brake assemblies... so I had to make a frantic call to a mate (thanks Gary! ) and drag my youngest daugther (thanks Bethan! ) out to hold a crowbar on the end of the shaft to get the diff out -



It's already parcelled up, with the ARB, and awaiting collection by UPS, to wing it's way over to the God-of-gearing, Rockwatt

Meanwhile... the rest of the day had been spent wiring up most of the control panel -



So the front winch controls are working, ARB compressor and actuator, front LED light bar, pair of horns, dual battery split charge...



So the new round red and blue push switches are the horn and flash for the front LED bar...

And note the lighter has been removed and replaced with a USB charger (thanks again to Gary for that for picking it up from an expedition event).

And the CB is installed where the ashtray used to be, with the aeriel on the front winch bumper -



And the iPad holder (to go with the charger), CB Mike and Extension Speaker (to right of Speedo out of shot)



And, I made a start on bolting the rollhoop in, but ran out of the correct size bolts, so will nip out and get some of them today :laugh:



So the Jimny is sat waiting for the diff to come back...

A few more bits to do while it's waiting though

I'm all done in just reading about it let alone doing the job, well done Bethan .......

Tadpole wrote: I'm all done in just reading about it let alone doing the job, well done Bethan .......

LOL :laugh: Thanks Tadpole... she quite enjoyed helping for a proper girlie... she's normally out doing ballet or acting and singing, not helping Dad by levering a shaft with a great big dirty crowbar... another pair of willing hands certainly helps! The missus normally pulls a face and sulks out to help :whistle:

BigJimny breather install today



Note that I've added the 5 port manifold, as the Rockwatt Rocklobster box -



... that I got had an 8mm OD breather elbow on the top, so I fitted 8mm pipe into that when I was installing the transfer box... that then -



Pops out from behind the engine and fits into the right side of the manifold, then another piece of 8mm tube comes out of the leftside and sweeps up the driver's side wing and through the black plastic moulded panel under the windscreen...



... and then up the side of the Safari Snorkel and into the snorkels head... highest point on the vehicle, not that it's going to wade that deep... I'd have drowned by then! :laugh:



It just needs a couple of P-Clips to attach the breather tube to these two mounting bolts on the snorkel now...

I then turned my attention to the axles, starting with the rear as the diff is out and has gone to Rockwatt the God-of-gearing for him to weave his magic over it and combine it with the ARB air-locker I've also sent him...



Whipped the breather cap off and inserted the tap into the top... I've never tapped before, so was pleasently surprised how easy it was!



I then carefully threaded the fitting it and tightened it up... again, surprised at how easy it turned out to be!



I then ty-wrapped the breather tube up the offside radius arm, and then along the brake lines past the transfer box, and up...



... behind the engine and into one of the manifold block's ports...



Then the front axle (A small amount of swarf may have fallen into the axle whilst I was tapping the front axle, but this is soon going to be rebuilt with 26 spline shafts and an LSD, so it will have the oil changed soon...)



And into one of the other ports on the bottom of the manifold - note that the third one has a blanking plug in it for now, until I can get to the top of the gearbox and fit the breather there...

So, a very easy breather kit to fit... I must admit I was a little concerned at the thought of internally tapping the existing breathers, but it's a doddle in reality! Many thanks to Martin! These breather kits are available in the BigJimny store.

As standard the kits come with T-pieces to splice the breathers into one long run of breather tube, like in the picture below, from the full instructions linked here.



As mentioned at the top, I only added a manifold block as my Rockwatt Rocklobster transfer box had an 8mm OD breather elbow fitting already on it, and I wanted to run the breather tube up into the head of my Safari Snorkel...

Tidying up jobs today...



P-Clips arrived and fitted, nice and tidy job



ARB compressor all wired and plumbed up...



All new wiring tested and tidied up with ty-wraps... iPad charging socket now working (blown fuse), it replaced the cigarette lighter... iPad in the right place for viewing with a flick of the eyes...



Little fiddly bolts fitted that stop the radius arm guards rotating... they also act as good mounts for the ABS lines...

Also fitted a reversing alarm ("beep beep beep") into the nearside rear light cluster, just so Phil-S won't reverse into me again if I'm still manoeuvring LOL :laugh:

So, all ready for the Lakes next weekend, just needs the rear diff'n'ARB which is coming back from Rockwatt the god-of-gearing... he's despatching tomorrow, monday, to arrive with me tuesday, for fitting on wednesday... (my day off)

Just need to load tools and spares, and we're ready to go! :woohoo:

Then... we've decided - due to other commitments - our "little group" is having August 'off'', so that leaves me time to get the 26 spline shafts and LSD into the front axle... does anyone know someone good with gearing to rebuild the LSD into my Jimny front carrier? It needs the bearings swapping over from the original diff onto the LSD, and the backlash setting up properly... can anyone think of someone capable of this..?

Hee hee, better warn Rockwatt that my front diff will be on it's way too then? :whistle:

Dave

MMS from Rich "Rockwatt" last night...



The rear diff with ARB fitted, and ready to come back