#ZedShed Project Filbert - (Nutty_Hazels Z3)

[GazHyde]

So it's that time of the year when @Lee opens his surgery for beleaguered Zeds. This time it's @Nutty_Hazel's Filbert getting some more TLC! Filbert is a 2000 2.0 6 cylinder.

Tonight was a quick session to get Filbert up on the axle stands, and look to get the exhaust off. This will then give us a clean run tomorrow evening to drop the sub-frame and get it on the bench for dismantling. A few pictures from the evening so far.

Poor Filbert looking all nervous!

Up in the air ready to get the wheels off and give him a good visual inspection.

Spare wheel mucky and probably could do with a new one at some stage, but not in anywhere near as bad condition as some we've seen.

Getting to the nitty gritty... New diff bush required as this one has failed - plan is to replace as normal using a PowerFlex as they are incredibly easy to fit.

Exhaust is off. This one had conventional nuts holding it on at the front (unlike the studs on my 2.2i), and took some convincing but came off relatively easily compared to others. The exhaust rubbers on the rear wouldn't come off for some reason despite both of us going at it - so we cut them off!

Rear disks are a little shabby - will go down on the list as an advisory

View of the rear beam bush which are completely shot! Better pictures when the subframe is off.

 

[5harp3y]

I need to get involved with this. Im only down the road too

 

[Lee]

I need to get involved with this. Im only down the road too

Come down mate I'm in chineham. I've been following your progress on pistonheads

Me and gary crack on from 6pm. Pm me and ill send you my address.

Lee

 

[Low Rider]

How wonderful Dr Lee has opened his surgery.

 

[hard top]

Christ, the year has flown by......

 

[Jonno Bee]

Lee, Gaz thanks for taking the time to post this with clear photos. Ideal time for me as I plan to re bush the rear suspension this winter.

Cheers,

Jonno

 

[5harp3y]

Come down mate I'm in chineham. I've been following your progress on pistonheads

Me and gary crack on from 6pm. Pm me and ill send you my address.

Lee

Away with work tomorrow but would've loved to, I'm only in hatch Warren

 

[zedonist]

I bet there both wearing jumpers though...

 

[Brian H]

I,love these projects, keep us updated

 

[Nutty_Hazel]

A Nutty note from Filbert, he can't thank @Lee @GazHyde enough for the work they are doing.
A big thank you for posting thread so I can see all his bits!!!! I like looking at Filbert's bits
I'm missing Filbert not being in the car port.

Should Filbert be back in Devon by November is anyone up for Al frescos in Dartmouth [USERGROUP=16]@West Country[/USERGROUP]

Will possibly be last chance to have the tops off and wind through our hair (excluding you baldies) sorry could resist

Nutty-Hazel - Filbert

 

[t-tony]

I'm sure Filbert is in great hands Hazel. I'll admit to a sunroof but that's as far as it goes.. Devon's a bit of a stretch from Lincoln but I hope you have a good few days to enjoy the "new" Filbert.

Tony.

 

[GazHyde]

This evenings work was an absolute breeze! 2 1/2 hours and the rear sub frame is up on the bench and stripped down, in fact we had another early night. We will now be waiting until Saturday before getting the rear beam bushes pressed out and new ones back in. They aren't the worst we've seen, but definitely in need of changing.

Some more picture below for your viewing pleasure

Trolley Jack under the diff ready to drop the sub frame. At this point everything is disconnected - brake lines, handbrake cables, rear shocks, prop shaft and so on.

15 minutes later there it is in all its glory!

We then take one end each and pick it up and put it on the bench so we can start assessing and breaking it down.

This is probably one of the most common issues we see on the Z3, one hand brake cable worn completely through.

The state of the beam bushes and diff bush

View: https://youtu.be/jgUhX2-0CF0


Drop links have seen better days and are starting to perish

Err, this again tends to happen - the centre of the OEM diff bush pops out with little pressure.

Favoured method for removing the outer metal ring of the diff bush. Hacksaw through, and then tap out with a hammer and screw driver.

All torn down and that's it for this evenings activities. We've removed discs, pads and handbrake shoes, the hand brake cables from the hubs, unbolted the rear beam from the swing arms and differential. Once we have the rear beam bushes changed, then assembly is just the reverse!

Total time so far, a very leisurely 3 1/4 hours. So far Filbert has been one of the easier Zeds to work on

 

[Nutty_Hazel]

I'm sure Filbert is in great hands Hazel. I'll admit to a sunroof but that's as far as it goes.. Devon's a bit of a stretch from Lincoln but I hope you have a good few days to enjoy the "new" Filbert.

Tony.

Thank you t-tony, I'm sure I will and so will Filbert weather permitting

 

[t-tony]

This evenings work was an absolute breeze! 2 1/2 hours and the rear sub frame is up on the bench and stripped down, in fact we had another early night. We will now be waiting until Saturday before getting the rear beam bushes pressed out and new ones back in. They aren't the worst we've seen, but definitely in need of changing.

Some more picture below for your viewing pleasure

Trolley Jack under the diff ready to drop the sub frame. At this point everything is disconnected - brake lines, handbrake cables, rear shocks, prop shaft and so on.
View attachment 22538

View attachment 22540

15 minutes later there it is in all its glory!
View attachment 22541

We then take one end each and pick it up and put it on the bench so we can start assessing and breaking it down.

This is probably one of the most common issues we see on the Z3, one hand brake cable worn completely through.
View attachment 22542

Drop links have seen better days and are starting to perish
View attachment 22543
Err, this again tends to happen - the centre of the OEM diff bush pops out with little pressure.
View attachment 22544

Favoured method for removing the outer metal ring of the diff bush. Hacksaw through, and then tap out with a hammer and screw driver.
View attachment 22548

All torn down and that's it for this evenings activities. We've removed discs, pads and handbrake shoes, the hand brake cables from the hubs, unbolted the rear beam from the swing arms and differential. Once we have the rear beam bushes changed, then assembly is just the reverse!

Total time so far, a very leisurely 3 1/4 hours. So far Filbert has been one of the easier Zeds to work on
View attachment 22547

You two will soon be able to do these with your eyes shut Gaz. That's how my H/B cables were on my Z3 too. Strangely that not an M.O.T. fail as long as the parking brake effort is good enough. That's why they say as a tester you have to take off your mechanic's head and wear your tester's head.

Tony.

ps. Great work guys.

 

[GazHyde]

You two will soon be able to do these with your eyes shut Gaz

We've pretty much honed the process now Tony. We have invented special tools for certain tasks, for example one to punch out the hand brake cables completely from the hub. But that said, we still get stuck with stubborn or corroded bolts/nuts no matter what preparation we take!

 

[t-tony]

There's always something to catch you out mate, but that's what makes it enjoyable, it's a challenge. Best if it's a hobby though
Good on you lads.

Tony.

 

[Mint]

Great work/read @GazHyde & @Lee. Keep the pictures coming...

 

[La_vida_diver]

That is Fantastic progress! I am so pleased it has come apart well. When Hazel got the car we had to rebuild the front end completely. New Macpherson Struts (Bilstiens), a calliper (It was seized and the guy had replaced one pad to get it through an MOT, from memory we also did front disks and pads and banana bars. I think we also put braided hoses and replaced most to the brake lines with the Bronze type at the same time. Again so that she would have a long life with the car.

I know she had an Advisory on a Banana bar bush this year, but the front was in a really bad state to start with when she got the car.

Although @Nutty_Hazel doesn't do a lot of miles Filbert did get a Flush and new oils and filter when she got him and even though the service did not suggest another it got it again this year so the engine with luck is all nice and clean again as we are sure the previous owner was not lavish on his oil changes and probably waited till the lights demanded it.

So the fact that the rear has come apart so well and will be refurbished is going to give @Nutty_Hazel a lot of years of pleasure with Filbert. Can't thank you guys enough!!

I had adjusted the rear handbrake three times in the last two years and poor @Nutty_Hazel just kept complaining about the handbrake (I was thinking she was just a weakling on the handbrake.... I completely missed that a cable might be duff. Egg on face this end)

I really wish I lived up there it would be so much fun getting involved!

 

[GazHyde]

With the amount of thick gooey sealant sprayed on the underside, I'd be surprised if you could find the hand brake cables Duncan

 

[La_vida_diver]

With the amount of thick gooey sealant sprayed on the underside, I'd be surprised if you could find the hand brake cables Duncan

Yes that was supposed to be Waxoil but I think it was something else but it all went on when everything was dry last year not long after the paint had been done in order to try and extend the life of the car as @Nutty_Hazel is just dotty about Filbert