#ZedShed Millers Z3M overhaul (Gearbox & Subframe)

[Lee]

Been a good couple of days. Lots of little jobs and some head scratching.

first up building the new lollipop bushes.

next I got some fresh paint on all of the callipers and brackets. These took some serious hours to clean up.

not looking too shabby

Next the diff cover needed some love. New bush and sensor bracket. The insides, clutch pack LSD

fitting the new bush. Very easy in a vice.

refitted, new gasket and bracket also fitted.

then gave the diff a coat of paint. There was some serious corrosion on this diff, looked a lot better than I thought it would.

next was some head scratching. In order to replace the front offside brake line complete to the abs pump the engine would need to be removed. So I joined a new bmw line behind the arch liner, least in the future it will make changing them a lot easier. I ended up doing this both sides.

then the passenger side.

brake flaring tool works wonders, makes it a doddle.

The old lines were seriously past it.

Once they were both sorted I then did a dry run of all the front hardware. I use this as a way to find out what bits I have missing plus if I need to make any modifications. Safe to say everything fitted well, I was missing a lot of fixings though.

both front brake carriers needed the threads cleaning out.

next I assembled the KW front coilovers and trialed them out with everything else in place. Drivers side.

passenger side. I would just like to add not my choice in brake line colour.

these coilovers you can adjust the rebound from the bottom, really smart.

If anyone’s interested in these coilovers here is the model number.

 

[Lee]

Next I fitted the new clutch and flywheel kit. The flywheel.

Lines up with the clutch disc.

then all locked in with the pressure plate.

another nice job was fitting the tank straps. The straps were there but no fitting kit so I raided one of the kits I keep in stock. Miller you must have them stashed somewhere.

I had some spare padding from Mazza so the bottom strap was padded out.

List of jobs is getting less n less. I have another trip to BMW to collect the final bits and bolts that were missed and it will be the sprint to the finish. I’m hoping to get a call about powder coating soon

Looking forward to fitting the rear coilovers. These will need setting up at some point. I’ll stance the car but Miller might want to corner weight it and make some adjustments. I’ll do a few test drives and set it up like my old M was.

 

[andyglym]

Quality stuff on the brake lines

 

[Lee]

Quality stuff on the brake lines

I was a bit gutted really. Wanted to fit complete new lines.

 

[andyglym]

I was a bit gutted really. Wanted to fit complete new lines.

Big job to get the engine out v's a good work round though

 

[Dino D]

Loving the front end ‘by Ann Summers’

 

[miller1098]

Lovely brake lines could do with some more colour .the suspension looks mint and should be nice to set up.

 

[Dino D]

Lovely brake lines could do with some more colour .the suspension looks mint and should be nice to set up.

that’s going to be night and say different going from dead stock stuff to that!

Ask Lee for the blue fluid....
Might clash with purple though

 

[Lee]

So today was half running around collecting stuff half assembling the front end.

first up was collecting the powder coated engine bits and they look so good. Even though I did ask for a matt finish I got a gloss finish and it still looks good.

Really impressed with the finish. This might be a thing going forward now with the engine covers. The cost was very modest. Next I popped into BMW to pick up last of the missing fixings. Then it was the alloys, these look the nuts.

they fitted shorter valves for a cleaner look.

these will stay in my car till they’re ready to be fitted.

With only a few hours left of the day I decided to sort the split hoses up front and fit the rocker cover.

while everything was out it was worth cleaning the ICV (idle control valve) she was clean so nothing to report.

when I removed the ICV it showed a broken line on the vacuum system. The little 3mm hose each side had crumbled.

I like easy fixes like this. Heat gun and some new hose she’s like brand new.

Next i fitted all the new hoses ready for the plenum. I’m leaving this off till the gearbox is back in. Quick wipe now ready for the plenum.

tomorrow I’m planning to fully assemble the front end and build the gearbox indent pins.

 

[Dino D]

Nice.

Those wheels look very heavy, don’t want to put your back out.

I’ll pop over and give you hand lifting them out of the car for you.
Just leave the car open - got to keep Covid safe - so I’ll just lift them out and be out of your way in no time

Friday lunchtime good for you I’ll bring

 

[miller1098]

Under the bonnet will look so much better the rocker cover looks mint

 

[TrevD66]

I think the whole car will be mint once completed.
Looking brilliant....
Wasn't sure what the powder coated rocker cover etc would look like but have to be well chuffed with the result.

 

[Lee]

Had a cracking couple of days on Millers Zed. Made some serious progress and she’s very nearly complete. Friday started off with fully bolting up the front end then doing the gearbox indent pins.

Gearbox ready, tools on the left and new pins in the bags.
First pin removed.

Easy pins done first. Interesting to see the redesign between old and new pin. Slightly narrower too.

Easy pins done.

Next up the harder pins and the cause of the leaning 5th gear. These didn’t cause any issues these can be pain because you need to break the old sleeve and pull it out without dropping debris into the gearbox.

followed the job up with a fresh pivot pin, new linkage bush and pivot arm, the arms wear more than you think they would.

I finished Friday off with removing the old throttle cable, this was a serious leg workout to operate. Also gave the half shafts a tart up.

throttle cable well past it.

so today was full steam ahead. The rear underside got brushing down and hammerite waxoil sealing along with the new brake lines.

brake lines.

the main event always is the complete rear assembly. I’m really happy how this turned out considering how bad the corrosion was.

close up.

At this stage the rear end takes minutes to install. Along with the stainless steel V3 coilovers the back end looks mint.

so much shinny.

that’s how the beam bushes should sit. Nice gap between the plate and bush.

We also stuck some fresh paint on the discs to clean them up.

rear.

very nearly done now. Some front end to reassemble and brake line bleeding todo. Cant wait to test drive.

This temp sensor is giving me a headache, the temp gauge in the centre console looks like it’s not been working for a while. God knows what happened to it.

Once she’s done everything will need a good dusting and wiping down. Hard to handle anything without it getting covered and you can see in most of the photos finger prints, rust dust.

 

[JimHats]

Looking great! Can I ask a quick question, how long is the throttle cable? I just purchased one but it looks oddly small. Want to check it's similar before removing mine!

 

[miller1098]

Had a cracking couple of days on Millers Zed. Made some serious progress and she’s very nearly complete. Friday started off with fully bolting up the front end then doing the gearbox indent pins.

Gearbox ready, tools on the left and new pins in the bags.
First pin removed.
View attachment 175805Easy pins done first. Interesting to see the redesign between old and new pin. Slightly narrower too.
View attachment 175811
Easy pins done.
View attachment 175807
Next up the harder pins and the cause of the leaning 5th gear. These didn’t cause any issues these can be pain because you need to break the old sleeve and pull it out without dropping debris into the gearbox.
View attachment 175809
followed the job up with a fresh pivot pin, new linkage bush and pivot arm, the arms wear more than you think they would.
View attachment 175813
I finished Friday off with removing the old throttle cable, this was a serious leg workout to operate. Also gave the half shafts a tart up.
View attachment 175815
throttle cable well past it.
View attachment 175817
so today was full steam ahead. The rear underside got brushing down and hammerite waxoil sealing along with the new brake lines.
View attachment 175819
brake lines.
View attachment 175823
the main event always is the complete rear assembly. I’m really happy how this turnt out considering how bad the corrosion was.
View attachment 175821
close up.
View attachment 175825At this stage the rear end takes minutes to install. Along with the stainless steel V3 coilovers the back end looks mint.
View attachment 175827
so much shinny.
View attachment 175829
that’s how the beam bushes should sit. Nice gap between the plate and bush.
View attachment 175831We also stuck some fresh paint on the discs to clean them up.
View attachment 175833
rear.
View attachment 175835
very nearly done now. Some front end to reassemble and brake line bleeding todo. Cant wait to test drive.
View attachment 175837
This temp sensor is giving me a headache, the temp gauge in the centre console looks like it’s not been working for a while. God knows what happened to it.
View attachment 175839
Once she’s done everything will need a good dusting and wiping down. Hard to handle anything without it getting covered and you can see in most of the photos finger prints, rust dust.

After wiping the tears from my eyes after watching the rugby this has bought a smile to my mug

 

[hard top]

After wiping the tears from my eyes after watching the rugby this has bought a smile to my mug

Oops ....

Posted at 23:33
WATCH AGAIN: Last gasp Dulin try breaks Welsh hearts

 

[Althulas]

Those temp senders really take a hit to corrosion. Bloody hard to get hold of as well. Searching for one shows up NLA, but found one site with 12 in stock for about £130. I’ve been looking on the VDO site for a replacement, it might be worth a look https://vdo-webshop.nl/en/temperatu...emperature-sender-140c-m14-4103590690159.html at a more reasonable price.

I’ve just done some more trawling as I vaguely recall a thread on an alternative VDO sensor that’s close to matching the original one https://www.z3mcoupe.com/forum/foru...al-discussion/17377-outdoor-temp-sensor-mount

Same as the one I found but will take a while to get here but at £24.99 delivered

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[Lee]

Looking great! Can I ask a quick question, how long is the throttle cable? I just purchased one but it looks oddly small. Want to check it's similar before removing mine!

I believe there's only two types for our zeds. One has a curved metal sheath on the end. I can measure it when I'm back in the garage.

 

[Mint]

Another brilliant build, well done ZedShed HQ

 

[Mazza]

Another brilliant build, well done ZedShed HQ

you’re not wrong !!! Saw the build progressing yesterday after an essential journey to Basingstoke
Sorry @miller1098 , Lee and Trev would probably have had it finished by now if I hadn’t kept them talking .
So much good work going on and lots more than we see on the forum, plus loads of help with my project. The parts that Lee has had powder coated are absolutely pristine so lining up loads of bits for my build.

.....Plus I called in on @Alan Slade and Maxine in Porchester on the way home (essential honest !!!) just to make a delivery . Was really nice to see them .... and Bertie