Honey Badger the Y60

[MudRunnerTD]

1) Anyone knows what is the purpose of that white plastic that was loose inside my tank? This is a diesel tank BTW.

2) My tank breather tube has this black thing on the end. I am not sure if it is supposed to be like this or if it is broken and missing some sort of filter or check valve. Anyone knows how it is supposed to be?
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PS.: filler neck and breather tube will be galvanized eventually when the car comes back from bodywork to my garage, so I can start addressing every minor detail one by one. Can't wait for that to happen...

Hi mate. nice build thread. the breather should have a big Bell like plastic case over it. it is designed to create an airlock if in goes into deep water. Think inverted glass pushed into a sink of water trapping the air in.

a 300ml or so bottle of water with the bottom cut off and the neck taped onto that black bung will do the same job.

[BrazilianY60]

the breather should have a big Bell like plastic case over it. it is designed to create an airlock if in goes into deep water.

Thanks @MudRunnerTD.
Now that you mentioned it got me really curious to see how that look like. I could not find any reference in the FSM, but remembered this time to check the Partsouk catalog and it is listed as 17333 breather hose cover... Ended up finding a picture from Patrolapart. Looking now to find a picture of it in place, or maybe taken apart, to have an idea if the connection is sealed or what.

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[Brissieboy]

Looking now to find a picture of it in place, or maybe taken apart, to have an idea if the connection is sealed or what.

If it wasn't sealed at the top then it would not be effective as an air pocket. I would suggest that it does need to be sealed at the top.

[BrazilianY60]

Found a picture on this thread:
http://www.nissanpatrol.com.au/forum...nk-Breathers!!

[BrazilianY60]

Engine came back from the machine shop looking top notch. They even painted it black.

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New filter in the airbox:
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New belts and fan clutch. Looking back at it now, I should have bought a new fan as well:
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Those hose fittings that I had to work around:
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And finally, the first idling! Sounds pretty good to me! My first 6cc engine, my first diesel, all at once!


How it sounds after warm. Very little noise from the tailpipe, but super loud at the cab. Later I discovered that the exaust flexible joint was toast. Fixed that. Still loud. Put the square intake tube and the cyclone back, still loud. Figured out a lot of the noise was coming from the square intake pipe to square airbox joint. Put some adesive foam tape to make it more sealed and that helped a lot.


Here it is intake+cyclone but I believe before the foam tape seal:


Testing the A/C idle-up actuator:


I was very happy with how the engine rebuilt went!

[Bigcol]

great job, very impressed with your resourcefulness, we sometimes forget just how hard it can be to get "goodies" for our beasties when we have everything we could need sitting locally on a shelf ........

[BrazilianY60]

Thanks @Bigcol.
Yeah, my goal with this restoration is to use everything I can from local market, when it can be accomplished with small, non safety related adaptations. Other then that, I have been able to source some parts in Paraguay, Uruguay, Argentina and the farthest of all so far, Australia.

[BrazilianY60]

I always knew I would have to check every single nut and bolt on the car, but the plan is to choose an area to work, disassemble, study the manual, evaluate needed parts, source equivalents or import, etc. But sometimes, you don't have the chance to choose an area to work, the work simply jumps in front of you begging for attention.

This was the situation with the front axle. When the tow truck dropped the car at the mechanic for the engine work, while we pushed the car into the shop, I noticed one of the front axle wheels was clunking when steering, and upon inspection, kingpin bearings were broken, allowing movement on the camber angle. So while the car was there, I studied the bearings and seals on the hub to find out that absolutely not a single one was used in any other car over here, so nothing available. Decided to do my first overseas order from OnlineAutoParts. Got a pretty nice swivel rebuilt kit plus some kingpin shims of different thickness to be able to properly adjust.

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Very stoked with how nice the kit was!

Unfortunatelly, in the anxiety of being "proactive and efficient" in getting parts, at this first time I failed to do things in the proposed sequence that I have stated above... "disassemble, study the manual, evaluate needed parts..." I have just assumed that was all I needed for the front axle without first dissembling it. I discovered that I had an issue with front brakes, front CV joint and may still have an issue with front pinion bearings. So, lets treat this one issue at a time...

All swivel/knuckle bearings and seals in place, when we were about to put the axles back in, we noticed one CV joint had a crack... frustrating... at this point the engine was close to be returned from the machine shop (it takes a while to import goods) so no chance to try to source another one, that could as well have been part of the freight of some brake parts that I had to buy and were already in country (more on the brakes later). I am ready to take all the flames, but I ended up taking the CV to a "parts recovery shop" to be welded, a very common 3rd world practice around here. Not proud of it at all... There, the CV was broken apart, welded inside and out, sanded inside/out, bearing races are bored to the smallest next available bearing-balls size to remove any wear hump it may have, balls replaced, put together and grease-packed.

The crack
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Outside weld
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Inside weld
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Final "product"
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[BrazilianY60]

Front brakes were mysterious at first inspection. The pad didn't touch all the disc, leaving a gap of disk unused for friction. Upon removing the pad, I also noticed the pad wasn't touching completely the disc as well, leaving some part of the pad out of the disc, and thus cutting at the friction material instead of consuming it evenly.

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Then I checked the pad part number... WTF!!! It was for a Ford Fiesta!!!
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Removed the caliper just to find this monstrosity! A new "ear" had been welded to the hub to accommodate for the smaller size of the Fiesta caliper! Just looking at it you can imagine the difference in order of magnitude of the Patrol and the Fiesta caliper.
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Took some measurements to see if the "ear to ear" distance would match some local truck, maybe an FJ40 or something, but no luck. If I had found a match, I would definitely use it, but I was not intended to adapt anything on the brakes.
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So I ground down the 3rd ear and new overseas order from OnlineAutoParts it was.
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Patrol calipers are huge in my opinion, despite being single piston. Here is a comparison with an UHF radio.
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These are the pads I chose:
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In place:
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To my surprise, the Patrol specific pad doesn't touch the inner center-line of the disc, as I was expecting. Also, what the frigging expensive thing those brake pad anti-rattle shims are! Wow! I just can't see myself spending that kind of money into some tin cans! Just used some high temperature silicone.
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As for the brake hoses, the Patrol caliper needed one with a pass-through hole fitting. Searched around and the FJ40 had the required fittings, and the length was similar to the one used on the Fiesta calipers.
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That turned out to be too long for my needs. It left me with a big loop in the hose, that was eventually touching the tires.


I had to improvise with some nylon clamps.
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Later, talking to a friend about this issue, he told me he uses Opel Corsa brake hoses on axle swaps he does, that it has the fittings I was looking for and a shorter length. This is a picture he sent me. I have later bought such brake hoses, but have not changed them yet because the car is still in doing body work.
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Car break is decent now. Not the "head to the windshield" type, but pretty decent. I still have to change the master and booster for the Patrol ones I already have, and will replace the hoses at the same occasion.

[mudnut]

Keep plugging away and it will be almost a brand new vehicle. You should get many years of service out of it.