Author Topic: 1989 Rocky F75 DL-51 Build Thread  (Read 2555 times)

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Offline Rusty

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #15 on: July 26, 2018, 07:08:40 PM »
Even after about 3000km, I am still getting some clanging and banging noises from the new leaf springs, presumably the leafs are moving over short sharp bumps and slapping together.  I contacted the supplier and they are going to check it out for me next week.

The next work required the dash out to get to the heater core...



Offline Rusty

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #16 on: July 26, 2018, 07:28:15 PM »
I'm not sure what made me think the turbo was not working properly as the car seemed to go pretty well for what it is, but I was suspicious and put a pressure gauge on the intake.  The boost pressure when accelerating wot in any gear was just over 1 psi, when it should be around 10psi.
So I removed the inlet side of the turbo and found the impeller was really notchy and sticky, not free spinning at all.  I know it needs the oil flow to get it going but still.  So I removed the exhaust side and saw the everything was intact but same notchy feeling on that side too.
I removed the turbo and too it to a specialist turbo repairer who agreed it needed attention, but through their suppliers could not source any parts.  The only options were no turbo or find anew one somewhere...  Luckily I found a new, genuine IHI exact replacement in Germany (presumably the last Rocky turbo on the planet haha) for a very reasonable price I received it after about 3 weeks.
While waiting, I replaced the side cover gasket, oil filter bracket gasket, oil pan gasket, oil/water cooler gasket, and o-rings etc

The photos are before replacing gaskets etc.  The oil leaks were pretty minor, but I can't stand oil coming out of anywhere...

Offline Rusty

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #17 on: July 26, 2018, 07:30:12 PM »
Oil pan gasket was lots of painful scrapping to remove whatever glue someone used previously, but its sealing fine now.


Offline Rusty

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #18 on: July 26, 2018, 07:31:38 PM »
The new turbo arrives:

Offline Rusty

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #19 on: July 26, 2018, 07:59:35 PM »
When refitting the turbo, I spent heaps of time making sure everything was spotless in the exhaust and intake sides as I any small shrapnel in the can kill the turbo on startup.  Obviously changed the oil and I also filled the oil lines to prime the oil supply to the new turbo.  I was thinking about how to crank the engine over without starting it so that I could build oil pressure before firing the engine.  After a bit of research on this, I decided it wasn't going to make much difference so all I did was start it up and let it idle for 5 minutes before stopping and checking for leaks.
It started as normal and there were no leaks, so very happy with that, just needed to take it for a drive to see what difference the new turbo made.  But before that I wanted to get the exhaust replaced and get it on a dyno to check air fuel ratio.  I since found out that running lean on a diesel isn't a problem, but running rich is not so good for exhaust temps.
So the new exhaust is fitted up.  I was a little surprised how much quieter the new exhaust was compared to the standard one.  It is 2.5 inches all the way from the waste gate with mandrel bends.  While I was at it, I had ports welded in for the pyrometer.

I also did the valve clearances before taking it to the tuner.



Offline Rusty

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #20 on: July 26, 2018, 08:01:24 PM »
Gauge setup involved a bit of messing around, still not 100% done, but presentable at least:

Offline Rusty

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #21 on: July 26, 2018, 08:12:17 PM »
I still haven't got to that inclinometer fix, but I will someday soon.

The next was to install some decent sound system as the car will be used for long trips to my remote hideaway... also needed to have hands free phone ability...

I chose an Alpine 200W RMS system, as I am sure this small car won't need any further amplification.

There was a lot of work needed to mount the four speakers properly and add the sound deadening material.  It was a real PITA fitting the head unit in the space provided, I had to customise the mounting box, but I made it after about 50 hours of messing around:


Offline Rusty

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #22 on: July 26, 2018, 08:23:45 PM »
Soon after I thought I needed a bit more bass from the system, so I added an underseat woofer with built in amp.  Probably didn't really need this if I had have realised how adjustable the head unit was.  It is possible to adjust frequency output for the individual speakers, but it made a nice improvement overall.
While I was mucking around with the rear seat, I lifted the front of it by 15mm with spacers, just to be sure there was no chance of the seat contacting the woofer when I roll it up.  I also added anti-rattle springs to these mounting points as rattling noises are annoying too.


Offline Rusty

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #23 on: July 26, 2018, 08:25:48 PM »
These photos make the carpet etc look filthy, but its not as bad as it looks haha.  Cosmetics are not that important to me with this car as its going to be used as it should be.

Thats about all I have time for today, but there is more to come.

Thanks for looking.

Offline brushhippie

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #24 on: July 27, 2018, 03:54:50 AM »
Glad you got it worked out! I too had to replace the heater core...avoided it for the longest time just from pure intimidation...was not near as bad as I thought it would be...have my inclinometer in the desk drawer here...trying to figure out how I am going to fix it...my biggest problem is the little plastic tab that holds it plumb has broken off....we shall see how that comes out...great work and thank for sharing!

Offline Rusty

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #25 on: July 27, 2018, 03:17:28 PM »
I found a good link on how to fix the inclinometer in the Rocky a while back, but havent done it yet.  Unfortunately the photos have expired, but the words are detailed pretty well.

Have a read of this:

http://www.offroadexpress.kiwi/Forums/viewtopic.php?t=9561

Offline Rusty

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #26 on: July 27, 2018, 11:04:59 PM »
So the next job was to do the swivel hubs as the left hand side was weeping oil from the freewheeling hub and the knuckle.  When I removed the FWH on the passenger side, I found that someone had stripped the treads for the cap, or rather, broken them right off and sealed up the gap by gluing two of the hex head screws with some goop.  Nice... so now I need to find parts or replace.  Ended up finding secondhand AISIN hubs.  I pulled them apart and cleaned/greased them once I had completed the swivel hub seals on each side.  I also replaced the front wheel bearings, brake rotors and brake pads while I had it apart.  First pic shows the grease had turned to oil in the left side knuckle...


I decided to dismantle the CV joint to regrease it properly...this was a bad decision as they are pretty much impossible to dismantle without stuffing them, so I ended up replacing the left side with a newie.

Offline brushhippie

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #27 on: July 28, 2018, 04:39:28 AM »
My problem with the fix is the original pin is in the groove with no way to remove it.

Offline Rusty

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #28 on: July 28, 2018, 12:07:55 PM »
Do you mean the second groove inside the CV joint BH?  Mine got damaged as someone else showed me how its done. Basically smashed it off with a big sledgehammer.  The correct way is apparently to cut around the old CV with an angle grinder, them remove the snap ring so you dont damage the groove on that end of the axle. I was thinking of replacing the axle too, but mine wasnt too bad really and I couldnt find another Rocky axle in the time I wanted to finish the job off.

Offline utherjorge

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Re: 1989 Rocky F75 DL-51 Build Thread
« Reply #29 on: July 29, 2018, 08:28:27 AM »
Rusty, awesome work!