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

...and then quickly got back into the garage to start on the front panhard... as you can see, it's a bit special as it has a kink in it... more on that in a minute...

The bushes went in the same though...



Using that 27mm socket and vice again...



And then the adjustable end again...



And so, this is how I'd left the front end in the intervening period since this saga started... The JimnyBits adjustable panhard rod bolted into the stock panhard bracket, albeit with the new Zanfi bracket left on top of it, and the original pitman steering arm welded up and refitted to get me out and about on a couple of 'laning trips with the rest of "our little group"



Now then, comparing the 'original' (JimnyBits) panhard rod (black) against the new Rockwatt stainless steel custom-made* panhard rod with a slight kink in it to get around the clash from running the Zanfi drop pitman arm with the Zanfi front panhard relocation bracket...

So, having removed all the existing parts... yup, time for another cuppa! And then back out to start reassembling...



That's better! the Zanfi parts now sit alright together (I must point out they ARE designed for left-hand drive vehicles, and they are not used to our right-hand drive Jimnys!) thanks to the Rockwatt stainless steel panhard rod with a kink in it so that the pitman arm (or rather the tie rod end connect to it) does not foul on the panhard rod...



Closeup!

And there you can see how the panhard rod now sits parallel with the axle, and the pitman arm, despite having a 75mm drop to it, sits freely above the panhard rod without fouling on it...



View from the front before going out for a test drive in the dark...



Plenty of room for everything to articulate without fouling...!!!

Many thanks to Rockwatt for coming up with the solution!

If you need anything custom-made such as these panhard rods to get round a glitch on your 4x4, have a chat with Richard "Rockwatt" Wattam on - richard@rockwatt.co.uk or 07921 222635. (+44 7921 222635)

Box of bits just turned up from the BIGJIMNY Store...



Ready for a front axle rebuild, as my diff is leaking around the seal to the axle, and a general engine service...

Front Disks, Sealant, Engine Sump Gasket, Oil Filter and Spark Plugs ...

Along with what I've already got in stock -



From BigJimny and JimnyBits...

New bearings and seals everywhere...

Time for some TLC...



I'd noticed a few drips of oil from the front axle, and could see it was coming from the diff to axle seal... So, after the new stainless steel kinky front Rockwatt-made panhard rod was fitted, and the new Zanfi panhard rod bracket (adapted to fit a right-hand drive) was fitted, and now worked happily with the Zanfi dropped pitman arm on the steering box - many thanks to Rockwatt! I thought it was time to address the leak...

You can see the oil in the bottom of the plastic tub.



Front axle guard off, and it's got a mixture of oil and water in it...



Oooh, that's been doing it's job then?! Lick of Hammerite before refitting it me thinks?!



Hmmm, that's strange...? I thought I'd start by removing the filler plug and poking a finger in to gauge how much oil I'd lost... but when I did, the oil flowed out?

Ahhh, a mixture of oil and water emulsified filled my catch container



Ah, yes, with the diff guard removed, it's clear to see there's been quite a weaping of oil from the diff, and water going back in the same way I assume...



Time to start stripping then... off come the brakes, as my mechanic mate had commented they pads were getting low when he was last laser aligning the front end for me...



Hubs off... plenty of mud in with the grease too... so it's a full strip and rebuild, new seals and bearings everywhere!



Hubs off and around to the local friendly garage to press the old bearings out and the new ones in... meanwhile, I started cleaning all the old oil and grease out...



Ah, yes, after sausage chips and gravy of course!



Diff cleaned out and faces cleaned ready for refitting soon...

Whilst I was getting some engine oil from my local oil specialists "Caldo", I asked them what was the best gunk to stick in between the two faces of the diff-to-axle seal, as I usually use standard (plumbing) mastic, and they said to contact my local agricultural engineering firm* and ask them for some Loctite "Strawberry Jam"

*As one of my neighbours and regular customers in my convenience store runs such an establishment I gave him a ring, unfortunately he was out and one of his staff took my call, and thought I was taking the mickey out of him, or someone was pulling my leg... "Strawberry Jam?!", he said suspiciously... Anyway, later that day, on his way home, my neighbour dropped me off half a tube of Loctite 510 for me to seal it all back together... sometimes refered to in the farming community as....... "Strawberry Jam" ?! :woohoo:

I'll also be using new bolts and spring washers and some thread lock as well!! No point taking chances of it leaking again!

More soon... no time to do it for about a week :S

S200KYS wrote: Time for some TLC...

I'd noticed a few drips of oil from the front axle, and could see it was coming from the diff to axle seal... So, after the new stainless steel kinky front Rockwatt-made panhard rod was fitted, and the new Zanfi panhard rod bracket (adapted to fit a right-hand drive) was fitted, and now worked happily with the Zanfi dropped pitman arm on the steering box - many thanks to Rockwatt! I thought it was time to address the leak...

You can see the oil in the bottom of the plastic tub.

Front axle guard off, and it's got a mixture of oil and water in it...

Oooh, that's been doing it's job then?! Lick of Hammerite before refitting it me thinks?!

Hmmm, that's strange...? I thought I'd start by removing the filler plug and poking a finger in to gauge how much oil I'd lost... but when I did, the oil flowed out?

Ahhh, a mixture of oil and water emulsified filled my catch container

Ah, yes, with the diff guard removed, it's clear to see there's been quite a weaping of oil from the diff, and water going back in the same way I assume...

Time to start stripping then... off come the brakes, as my mechanic mate had commented they pads were getting low when he was last laser aligning the front end for me...

Hubs off... plenty of mud in with the grease too... so it's a full strip and rebuild, new seals and bearings everywhere!

Hubs off and around to the local friendly garage to press the old bearings out and the new ones in... meanwhile, I started cleaning all the old oil and grease out...

Ah, yes, after sausage chips and gravy of course!

Diff cleaned out and faces cleaned ready for refitting soon...

Whilst I was getting some engine oil from my local oil specialists "Caldo", I asked them what was the best gunk to stick in between the two faces of the diff-to-axle seal, as I usually use standard (plumbing) mastic, and they said to contact my local agricultural engineering firm* and ask them for some Loctite "Strawberry Jam"

*As one of my neighbours and regular customers in my convenience store runs such an establishment I gave him a ring, unfortunately he was out and one of his staff took my call, and thought I was taking the mickey out of him, or someone was pulling my leg... "Strawberry Jam?!", he said suspiciously... Anyway, later that day, on his way home, my neighbour dropped me off half a tube of Loctite 510 for me to seal it all back together... sometimes refered to in the farming community as....... "Strawberry Jam" ?! :woohoo:

I'll also be using new bolts and spring washers and some thread lock as well!! No point taking chances of it leaking again!

More soon... no time to do it for about a week :S

What happened to that stub shaft?
looks like rust?

Hmm, mud I think, but haven't started cleaning them yet though...

You don't want to stick the diff in too heavily Dave as you have to get the bugger out one day. Normal RTV is good enough and can still be tricky to get the diff out with. I don't know what Suzuki use but it's pants.

I've had to help mates get diffs out of SJ's and Land Rovers and with no bolts in and a good whack with a rubber mallet and a fat Essex lad (me) hanging off of them, they still sit glued in place defiantly!

Strawberry Jam might be better on a tractor mind!

Kirkynut