Intro from Malaysia - WR7002 - C304

[geckoadventure]

Hi second post

I'm from Malaysia - most people call me GECKO (my nice neighbour he just calls the police hahaah) due to the large GECKO tatto I have on my arm. I have acquired a C304 (4 wheel model only) and in the process of restoring it.

As we pulled it out of the storage park with my BJ75 on 26/07/2010. It was not running but would tick over.




The BJ75 struggled to pull it it appears the brakes we frozen on.

ONto the tow truck and down to a performance tuning shop hahaha.



Once they removed the spiders and cobwebs from the tank it started.

THen they changes all the fluids.

But they could not fix the brakes so I made decision to do the DISC conversion first before the rust treatment.

I drove it around at nite for 2-3 weeks testing it out - without brakes and only using the gears and handbrake. I learnt what was good and bad in the truck and what needed fixing. Now I have a 40+ item list to attend to.

Then last Saturday I took it to the hospital (escorted by the BJ75) which was entertaining saw this on the way out. Oh yeah I burnt off a 22R powered LC II on the way up a hill it could not pass until the downhill part hahha.


This is it after being washed and driven for a few weeks. Mr Grumpy my neighbour hates it and all 4x4's the other neighbours in the street think its neat including the ("SIR") who I took his kids for a run in it now he wants to book a jungle trip with me.


The interesting one is my car illiterate neighbour she I quote "that engine sounds so sweet" its nicer than my Honda. Then where is that big beautiful 4x4 on sunday she asked.



Then the serious stuff removing all 4 wheels and portals - yeah yeah thats me working on the Jalopy.


Me working on the last wheel. The mekanik did 1 I did 3. Not bad for my first ever working on a Vovlo and no manual either.


7 hours later a A stack of portals


Once that was done it was over to the BJ75 and pulled the WARN 8274 out of it it has water in it and the new axle to be fitted and a new knuckle this week and new leaf spring bushes and it also has a brake problem.

We are going to put on in this round of fixes:
1. LC II Front Discs front and rear as this is a part which is readily available.
2. Install the WARN 12,000lb winch for REAR recoveries
3. Fix the taillights with LED lights
4. Fix the indicators
5. Fit new headlight wiring and H4 halogen bulbs and new reflectors
6. New radiator hoses and break hoses.
7. Battery Rack for 2 solar batteries and 2 120amp batteries and a 150AMP Alternator.


Once we
So thats my intro. I will post up stories as I slowly restore it.
The rest of the truck is STOCK.

I have previously been in (and out) a C304 during the RFC2007 when we got flooded and I was in the BJ75 in the same small convoy of 6 of us. I know what it can do - awesome. I cannot wait to take mine offroad here.

I also own a:
Toyota LC II - 13B-T monster very jungle ready
Toyota LC II 1KZ auto handbag jungle car
Toyota BJ75 - jungle ready
ISUZU pickup and
TOYOTA VIGO pickup.

My favourite is the BJ75.

[wrangler_tj]

I have a C303 and have also my brakes upgraded to disk brakes.
So if you have questions, I will pleased to answer them.

I used to conversion kit of omt-offroad from germany.
It uses Toyota brake calipers and disks.

I also replaced all bearings and all seals of the portals.

Regards.

[geckoadventure]

I have a C303 and have also my brakes upgraded to disk brakes.
So if you have questions, I will pleased to answer them.

I used to conversion kit of omt-offroad from germany.
It uses Toyota brake calipers and disks.

I also replaced all bearings and all seals of the portals.

Regards.

we are fortunate here beacuse of all the comp trucks running Volvo axles and they all been converted to disc there is huge knowledge and several engineering shops can get it done very quick.

Thanks for the offer my big question is the auto 4wd invoke how to still keep that with discs. How do you cater for the twin brake pipes at front u blAnk one off?

[geckoadventure]

I have a C303 and have also my brakes upgraded to disk brakes.
So if you have questions, I will pleased to answer them.

I used to conversion kit of omt-offroad from germany.
It uses Toyota brake calipers and disks.

I also replaced all bearings and all seals of the portals.

Regards.

we are fortunate here beacuse of all the comp trucks running Volvo axles and they all been converted to disc there is huge knowledge and several engineering shops can get it done very quick.

Thanks for the offer my big question is the auto 4wd invoke how to still keep that with discs. How do you cater for the twin brake pipes at front u blAnk one off?

[wrangler_tj]

I have a C303 and have also my brakes upgraded to disk brakes.
So if you have questions, I will pleased to answer them.

I used to conversion kit of omt-offroad from germany.
It uses Toyota brake calipers and disks.

I also replaced all bearings and all seals of the portals.

Regards.

we are fortunate here beacuse of all the comp trucks running Volvo axles and they all been converted to disc there is huge knowledge and several engineering shops can get it down very quick.

Thanksgor the offer my big question is the auto 4wd invoke how to still keep that with discs. How fo you cater for the twin brake pipes at front u blAnk one off?

For the twin brake lines, I put in a closet plug. What do you mean with the "auto 4wd invoke" I don't understand the problem?

[geckoadventure]

Pictures of the project.

Latest status is POTRALs with DISCS being assembled and fitted this coming week.

Rewiring of HEADLIGHTS, REAR lights and INdicators being done this week along with new fuse boxes.

Rear 12,000 WARN WInch being installed sometime this week also but not wired up thats my job later.

Maybe it might be ready to roll out of the workshop this week then it will be driven for a week before going to get the RUSTed front removed and replaced.

Fixed the passenger door lock up on saturday *_*

The portals being fitted with DISCS and BEARINGS


The finished product.

[M Wehrman]

++What do you mean with the "auto 4wd invoke" I don't understand the problem+++

If I deciphered the shop manual correctly,there is a resettable plunger off the brake pedal that will engage the ft axles if the brake pedal goes to the floor. For what reason,I don't know.
Mark

[geckoadventure]

++What do you mean with the "auto 4wd invoke" I don't understand the problem+++

If I deciphered the shop manual correctly,there is a resettable plunger off the brake pedal that will engage the ft axles if the brake pedal goes to the floor. For what reason,I don't know.
Mark

THanks for that brakes went to the floor as we had no working brakes.

Also found out when the engine is turned off the front wheels are engaged is this correct and when you start the engine they under vaccum are returned to two unless you move it to 4wd is this correct?

I will verify this when they start the truck this friday.

The project is slowly coming along - the wiring due to be finished today - the Warn m12,000 to be installed for REAR rescues this week also and the new DISC brakes finally ready to run. THen I can drive it around for a few days.

[wrangler_tj]

Now I understand!

Yes, their is a kind of automatic system. If you press hard on the brakes like an emergency stop front wheels are engaged to prevent the locking up of the rear wheels and stopping power is split to front and rear.

Their is also a contact on the left chassis-beam that indicated different brake pressure between left and right. If their is a serious difference, the contact will be engaged and the brake light on the dash will light up and stay on untill you reset the brake contact.

Any questions about it, let me know and I will help you out!

[geckoadventure]

Well after waiting almost 5-6 weeks brakes are done and more mods done.

Came out of workshop with new disc brakes working but not well so new master pump seal kit and strip and rebuild the vacuum pump and hoses and wow they work very well long soft travel.

Its now boasting Landcruiser II Front Calliper and new rotors and Pajero rear discs. but its not stopping well.

Took it to a workshop and they stripped the master cylinder fitted a new seal kit and stripped the 10 tonne Hino vaccum cylinder and repaired it and wow they told me it had brakes again. Not bad for a MYANMA mekanik who got instructions from the cantonese mekaink I told in broken english who only speaks Cantonese and I used bahasa and english and cantonese to explain what was wrong to him hahaha.

New air filter box fitted and vacuum lockers are to be swapped this week for air as cannot buy the rubber seals here

Does anyone know where I can get the locker diaphram rubbers from UK or europe please?

Its Almost ready for a trip to the jungle.


The new look with 6 stud FORD rims







Front Wheels now offset an additional 60mm with the FORD rims






Offset from the hub to the edge of the tire hs now widened the track 60mm each side.




The brakes in the Volvo are now AWESOME is all I can say long soft Travel and powerful extremely impressive for its weight and considering its a truck.


First offroad trip a shakedown run last Sunday


Spent all Sunday afternoon changing the two engine fan belts don't ask its a prick of a job as the alternator has been changed previously then we noticed the belts etc do not line up the alternator is 3-4mm out . THis needs to be fixed in the coming weeks.

Then we changed the radiator hoses as they had RUST in them. Then we tested out that mighty PTO winch yup it worked also.

By 5.00pm we are ready to go to the jungle Ulu Slim some 90k away.

By the time we headed into the jungle its gettting dark. Stupid us but we really wanted to test it out.

At the first steel bridge we take the creek and yes we got stuck as the Volvo stalled as it was missing under 2000rpm as I crossed the river.



Then we were stuck no way back and no way forwards and by ourselves duh!!!!!!!!!!!!!!! and then we realise only 2WD is working and we have no front drive




Cleaned out a rock or two from behind and then we reversed out and then drove over the creek at a faster speed hahaha. Up the hill and it was very slippery wet and muddy we decided to turn for home.

Then we only had high beam and a missing truck under 2000rpm.

Back home at 4000rpm down the highway with only high beam.


Home at 9.30 after driving flat out at 4000 rpm at 80k for the 90k home hahaha.


The perspex windows need to be replaced before it can go out at nite again its too hard to see out the front windows.

Monday Arvo Dropped the Volvo back to the workshop at Lunchtime to find out why the front axle not engaging and picked up the Landcruiserr II and drove it back to work the first time I had driven the Landcruiser in 5 days. They also to remove the radiator and flush it .

On the way to work.

1. WHats that long green thing in front - oh year a bonnet.
2. WHy do the brakes feel so heavy (and GREEN is a delight to drive) to push
3. Why does the steering wheel feel so vertical and FAT?
4. WHy does it not stop as good as the Volvo
5. Oh poop almost hit that car the brakes need too much pressure to work hahaha
6. Steering feels heavy even with power steering
7. Hey its got window wipers why do I need them
8. The Volvo sits better on the road - ooops whats wrong with me hahaha.
9. Damn where is that music coming from - oh really its got a stereo.
10. Wow its cool in here that airconditioning stuff really is cool.
11. Why do the front windows not open forwards and let air in?

[michael mcauliffe]

Does any body know how much the disc conversion kits from germany are ?

I live in Australia, so having replacement parts would be good.

Is there a similar kit from another supplier ? I'd like to keep the 8 stud wheel pattern if possible.

Cheers

mick

[wrangler_tj]

Does any body know how much the disc conversion kits from germany are ?

I live in Australia, so having replacement parts would be good.

Is there a similar kit from another supplier ? I'd like to keep the 8 stud wheel pattern if possible.

Cheers

mick

I think you mean OMT Offroad, just give Marc Schafer a call
he will tell you everything you need to know.

8 lug pattern isn't any problem.

I have the conversion kit from him and I'm very happy with it.

[michael mcauliffe]

Thanks wrangler_tj

i'll do some more homework and give Marc from OMT a call as suggested.

Cheers

Mick

[geckoadventure]

well next update 10 October 2010

new tempered glass in the front window and the perspex ones tossed away wahooo now I can see driving at night. now need new wiper motors are they volvo or LR items can someone tell me?

rear doors had new latches fitted so the doors no longer open by themselves.

Now I have to fix the PTO its slipping under load.

next is either diesel conversion or high ratio diffs or the bus factory for rust removal not sure which depends which one I can afford first

[wrangler_tj]

well next update

new tempered glass in the front window and the perspex ones tossed away wahooo now I can see driving at night. now need new wiper motors are they volvo or LR items can someone tell me?

rear doors had new latches fitted so the doors no longer open by themselves.

Now I have to fix the PTO its slipping under load.

next is either diesel conversion or high ratio diffs or the bus factory for rust removal not sure which depends which one I can afford first

Please let me know about the wiper motors, I also need a new one.

I also need a new master brake cylinder, can you get them?
Or do you have some order numbers or brand?