All you should need is a new bush from Ford - was $9 down here. Measure end float at the drive gear, and tap in the new bush to about same.
Did the EL on it's LPGi conversion 12 mths ago, doing same to the XH and of course the XR wagon on it's coil dizzy conversion.

Good to see your trip went well! It is a sign of a good car that breaks down near home not in the middle of no-where! You've trained it well!

LOL

Hey Peeps,

I have just finished all 100+pages of this thread just fixated on the entire story of BenJ + friends for the last 2 weeks solid. Yes, I made myself actually go back to the original Red EB build thread, because I just didn't want to miss any of the details, was so worth it

This thread with the Black Wagon is like a sequel that became more awesome than the origional, which is pretty rare. BenJ, your soul has been poured into your trusty steed and it shows (this is true for all modified rides when done right), and allow me to say she's a beauty.

I've been a bit of a lurker on this forum for the last couple of years, not really posting unless I had a specific problem I needed a group hive-mind to help with. But I've re-evaluated my usage now, there is now a real feeling of that modding bug biting more and more with every new "Next" link I'd click at the bottom, it was actually quite addictive because it was so enlightening.

Don't tell my wife but thanks to you I've actually been weighing up the idea of selling my beloved Skyline, (which has been sitting in the garage for the last couple of years, gathering dust, and being used like an oddly shaped shelf for the random junk that accumulates there), and grabbing the next straight bodied EB/ED I can find on eBay, so that I too can join in all the fun and hopefully create something worthwhile with my own two hands

Bravo, dont stop now!

:Jordan

Hi Jordan.

Thanks for the kind words.

Come on down to Liverpool one Friday night. We meet near Harry de wheels cafe and all are welcome.

Cheers
BenJ

IGNITION PROBLEMS SORTED

In addition to the other issues previously mentioned, I had another odd electrical gremlin during the week.

On occasion the temp gauge was playing silly buggers. It would either not respond at all and the needle would stay below the 'C' mark, and then later jump up to the correct position, or it would indicate a temp but then stay in the one position. In addition, if the needle was below the 'C' mark the A/C wouldn't activate the A/C pump.

On Friday morning before work, I decided to change the temp sender for a spare. This showed no difference to the odd behavior.

Hmmmm.

I have heard of the cluster motors failing, and went ahead and ripped out the Fairlane Cluster, dismantled it and swapped out the temp needle motor.

Installed the cluster, cranked it over . . . and over . . . and over!!!!! AHHHHHHHHHHHHHHH

The bloody thing wasn't firing again. I know for a fact that the engine will run without the cluster plugged in, so this had me stumped for a few minuets.

Then, LP reminded me of a previous occasion when the wagon wouldn't run, and the issue turned out to be water in the ECU plug.

DOH!

I have just driven a few thousand kays in rather heavy rain.

So I pulled out the ECU and sure enough, there were some drops of water in the ecu plug socket. I blew out the plug and the socket with the air compressor, reassembled it all, and started the engine up again.

Idled along quite happily.

I really must make a raincoat for the ECU.

It would now appear that the TFI module on the Wagon dizzy is quite ok, but I am pleased I found that the shaft has movement. Oh well.


CATYLIC CONVERTOR COLLAPSED

The other problem that had identified itself was a rather loud and annoying rattle from under the car. A quick check found the CAT to be the culprit.

After a chat with SWC, I arranged to go to his place last Saturday, and we spent the afternoon modding a factory cat to work with the Pacemakers and the exhaust.

This is what I found when I removed the old CAT.


It did feel a little strangled during the week, LOL.

Goes much better now, thanks SWC. You are a good friend.

Cheers
BenJ

There's an understatement!
After following you up and down that mountain to-day and through the chicanes [so thoughtfully provided by the State], I'd say it goes very well!! Sounds really good too.
Given how fully loaded the wagon was, the suspension work you've done came up trumps and sat the car great all the way. The Grey Whale wallowed in your wake.
The kids loved the chase, at least they screamed "We're all gonna DIEEEE!!!" in chorus, so I assumed they were having fun. The trip home was more peaceful, we all slept... except Leadfoot, I hope, as she was driving.
A good day, great to share it with you and yours.
Cheers,
Mac

I've heard that song before!!

Ahoy BenJ,

Better to not melt in the heatwave, so kind of understand no posts this past week but:-

Did you modify your ISC yet?

Is PaulC capable of operating in temps above 36C without a can in BOTH hands?

Will his epoxy cure BEFORE he applies it to the SECRET project?

Will the SECRET project stay SECRET for long?

Will there be civil war in Egypt?

Why is LPG sooo @#$%ing dear outside of Sydney?

Come on mate, these are questions of some importance that must be answered, you have a responsibility to us addicts of this thread.

So push on through the pain and sweat, TYPE SOMETHING, even one fingered, I can't take the suspense....

Sorry, nerves are going...withdrawals,,,it's only a car...it's only a car...it's only a

Help!
Mac

LOL

UPDATE - General Maintenance and other odds and ends

There has not been a lot of action on the wagon of late.

I have taken care of a few odds and ends as they have cropped up.

Antenna

Before my trip to QLD the auto aerial stopped going up and down, and was stuck at half mast. I ordered a new replacement mast, and finally got around to fixing it two weeks ago. What a PITA. I had to disassemble the motor as the toothed section had snapped inside where it coils up, but I got it there in the end. All fixed now.

Instrument Cluster LCD

When I replaced the Instrument Cluster after my quest to solve some of the previous electrical gremlins, the LCD stopped lighting up, so I pulled it all apart again and checked all if the connections/mods I have done. Not sure why they stopped working, but they are functioning fine now.

ICS Switch

I am not sure if I have mentioned this previously, but for well over 8 months I have been driving around with the ICS (Idle Control Solenoid) unplugged. I adjusted the base idle and it idles just right on both fuels at around the 750-800rpm. I had been getting a lot of rev hang with the ICS plugged in, and this meant that engine braking was almost non existent.

As part of having the A/C re-gassed, which is still working ok, I knew the idle was going to be a problem with the A/C compressor engaged. So I added a switch, mounted on the bottom of the steering column surround, to switch the ICS on and off as needed. This lets me use the ICS for cold starts, and for when the A/C is on. I intend to install a relay to auto engage the ICS when the A/C compressor is engaged.

Water Leak

During the recent heat wave we had here in Sydney, I noticed excess water under the car. It appeared to be coming from the overflow pipe, and a quick look around showed no obvious leaks. I checked the Radiator Cap and the rubber seal looked a bit sad. I grabbed a new one, and that stopped the overflow issue.

As part of the BARRA conversion, I intend to use all new water/heater hoses to eliminate any heating issues as best I can.

Tie Rod End

A couple of weeks ago I noticed a 'groan' while steering. Odd, and then a clunk developed the next day. I found time to get under the car, and found the right hand tie rod end boot was completely split and it had no lubricant at all left in it. I grabbed a new one and fitted it up. Fixed.

I have had a persistent leak from the steering rack, which I had hoped to fix when I replaced the pressure switch, but no such luck. The leak appears to be from the top rubber seal where the steering shaft enters the top. This is on my list of things to replace in the near future. The Green ED Ghia has a good rack in it. I will inspect it and if is ok, will swap it in soon.

Tow Bar Tongue

When I installed the rear MMM bumper bar, I didn't fit the tow bar tongue, and found I couldn't put it on with the bumper bar in place. Seeing as I need to tow a trailer this coming week, I had to find a way to fit the tow bar tongue.

I was able to source a different tongue with a higher step up (thanks SWC) and after a bit of black paint it was ready to go.

In the end, I had to remove the bumper bar, bolt up the tongue without the tow ball attached, and then slide the bumper over the tongue. The is no room at all for the bolts to be fitted with the bar in place.

Front Bar

The front bar is still broken, however a replacement part has been sourced. I was able to score a damaged BA XR bar (cheers MRE50L) as a freebie, and SWC has it for some surgery. Should turn out nicely and provide a home for an inter cooler when required.



Hope you are all safe and well.

Cheers
BenJ

HAHAHA
The funny s**t on these forums recently!

It's not been used in a very long while, so you won't know til it's in and running on how the seals and O rings are. Big risk IMO.
Overhaul it - they're a cinch . $40 seal kit should do it.

Alternatively, I've a couple of spare std pinion housings, and a couple of spare top seals.

NOT AGAIN



Got out of work yesterday afternoon around 4.30, walked to the car, got in, switched to start on Petrol, turned the key, and it just wound over, and over. Tried it on LPG, same thing.

BUGGER!!!!!

More spark issues. Damn!

Now, this isn't usually such an issue, except for where I park my car during work. I rent a car space in a unit block, which is down 3 stories and accessed via a car lift. No way the NRMA dude is going to be able to get a flatbed truck to the car.

After calling the NRMA, I decided to push the wagon into the lift. Luckily my car space is directly opposite the UP lift, so it was an easy push into the lift. Pushing it out backwards at the top at full steering lock is another matter all together. And I am dressed in my 'go to the office' gear. At lease there was a small ramp down from the lift area to the street exit, so I was able to roll out the driveway and park it next to the curb right on the street. PHEW!!

NRMA guy arrived 5mins later and confirmed a weak coil was the issue. He called the flatbed and I got a slow ride home.

Located two spare coils amongst my piles of parts and got the wagon going again within an hour after getting home.

That is now the 4th second hand coil on this engine. Time for a new one I think LOL.

Cheers
BenJ

your lucky yours is an easy fix.. my ltd is currently sitting out the front, plenty of spark, no injector pulse... and because it starts on fuel i cant run it on LPG either.... thinking maybe its the TFI module... i wish mine was a simple coil issue