FORD HYMER ENGINE GEARBOX AND PROP UPGRADE (FINISHED)

[JIM T]

On the little plate it says made in west Gearmany

[pete_the_4x4]

that is the best early transit camper i have seen

[JIM T]

that is the best early transit camper i have seen

(cheers mate .JIM T)

[JIM T]

20 th Jan 2008 2 hours.
I took the lift pump off and it looks like it is the problem ,it pumps ok but it don't suck at all so looks like a knew one will sort out the problem .
I made a bracket and mounted the air box above the engine, it was a good job no problems.
The next job is the prop shaft and center bearing bracket, I was going to get one from the scrappys but it looks like a small job to make one and I can make it adjustable , I sprayed over the welding and that was about it ,I still have to sort out the wiring ,the temp censor and the loose wires , and the floor of the cab I must have forgot something I all ways do.

[JIM T]

21 JAN 2008 3 hours work

I made a jig out of a piece of 3 x 2 and mounted the prop shaft on it , the distance between the gear box and the rear axle was 74 and 3/16 th of an inch. so I mark out were I wanted the prop to go on the jig and then cut the prop on the original weld . Then I cut a section out 6" long then tacked welded the prop back together leaving an 3/32" gap then I pro seeded to gas weld it ,it took all of 5 minuets I wrapped wet cloths around the universal joint so not to put to much heat into it, then I fitted the prop ,spot on I had to leave a 1"and a 1/4 gap in the middle for chasse movement that is the same on my MK 5 ,I think its called a cardan shaft not certain though .
Then it was the turn of the prop centre bearing bracket, all it needed was a piece of small channel drilled the same centres as the centre bearing and the two 1/2" nuts welding on I then pro seeded to place the bracket in position for welding to the chasse (waiting for rain to stop all in all a good 3 hours work.

[JIM T]

22nd JAN 2003 3 hours work
I welded the centre bearing bracket on ,it was very awkward to get the wright position with the MiG welder but I managed a good weld but it doesn't look very pretty (I should have done the prop be for the exhaust).Then I drilled the two holes for the gear box mount it was hard to mark out the position of the holes from under the cross beam but I managed it, I had to repeatedly shove the drill up and down to make the hole in the rubber belting . Then I found some bolts they had to be the wright length I did not want to compress the rubber to much it as to give with the movement of the gear box, so the bolts had to go thread bond , I put a lock nut on as well. Tomorrow I will fit the lift pump and bleed the air out the engine again ,I run all the fuel out of the pipes so I will have to bleed the high pressure side of the pump again ,all being well I can give the engine a good run .There's some wiring to tidy up yet and the engine needs an oil and filter change but that's about it, of course I still need to put the face back on that will be the last job .PS I driled two holes in the cross beam and fitted a exhaust clamp over the exhaust, it saved me having to make a bracket .

[pete_the_4x4]

getting there mate

[JIM T]

I hope to be driving her down the road in a few days mate I'm hoping for a bit more top end but a lot more low down ,the old York engine had nothing in her I just hope the diff does'nt stop her too much .

[rover]

Quality work Jim, keep it up mate

Rover.

[JIM T]

23 Jan 2008 3hours work
Thanks rover will do.
I fitterd the lift pump and bled the high presure side of the pump then just be for I flattened a second battery she started, I then fitted the rad and ran the engine for 15 mins then I change the oil ,there was a little smoke befor the oil change but after none at all there were no oil water or fuel leaks so Im'e dead chuffed It looks like I've got a bonzer of an engine thats all I was bothered about now to get the face back on and a road test

[rover]

Glad to hear its running well

Rover.

[JIM T]

24 Th Jan 2008 4 hours work
I finished the wiring and started to put the face back on the Hymer it wasn't as straight forward as I had thought, all the front had been drilled more than twice so the original holes were elongated but I use some drill screws and that did the trick .After messing about for an hour on a couple of screws then it was all but finished YES ALL BUT FINISHED I have to make a plate to cover the hole from the old gear stick and check the gear box oil but that was it finished 2.30 pm Thursday 2008 I was ready for the test run I had to do the school run so it would be 3.30 pm be for I got going .
TEST RUN
3.35 PM She started first time as always I had to shuffle the trailer, Mk 5 ,and golf out the way then I reversed down the drive she goes into gear smoothly I put her into first and I was off the clutch is a bit high but not too bad ,I pull to the end of the street and away it went she pulls very well 1st 2ND 3rd all have good power now into 4Th and she's still pulls I drove to the A1, then we set off down the motorway 4Th gear then into 5Th and she was still pulling, I drove for 5 miles or so only gearing down from 5Th to 4Th That was a first for me in the Hymer then I decided to open her up ,50mph came and went 55,60 65 70mph then a vibration from the front I slowed abit and it went .I travelled on for a mile or so the traffic was a bit bad but here was my chance she sailed up to 60 then I put my foot down to the floor 65,70,75 and the wind took a side swipe and I was all over the road so eased off and thought that will do me, she kept up with all the traffic and I was not gearing up and down all the time so off home for me and a bottle of bud to celebrate cheers .I would like to thank all who replied to my posts I would not have had the confidence to attempt the upgrade with out you and the Forum so I say thank you again BIG TIME Regards FROM JIM T. PS everything works I meen everything.

[Luke]

nice one jim well done mate and thanks for posting up your progress interesting to read and, i'm sure it will be valuable help for others

[rover]

Well done Jim

Rover.

[captain hook]

Well done Jim grand job done......

I had a Mercedes version in today for MOT...

I now want a Hymer badly, they are fine campers..

Anyboy know of a Ford one for sale?