This video demonstrates a systematic approach to troubleshooting and repairing vehicle electrical systems and mechanical components, including diagnosing battery drain issues, identifying short circuits through smell tests, and methodically disassembling complex assemblies like gearboxes and exhaust systems to identify and resolve problems.
Deep Dive
Prerequisite Knowledge
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Where to go next
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Deep Dive
PAINTED PERKINS! And more apart
Added:[music] [music] Yeah, folks. Nice Dave. Monday morning.
Yeah, we've had this dumped off over the weekend. Battery problems. So, first job we got to shoot off and get some.
Anyway, folks, thanks for your comments, likes always. Much appreciated. Yes, we're going black and silver on the 1200. Speaking of the 1200, my one, which is that engine there. Just picked the batteries up. And we've also picked some other bits up. We got the injectors back. Been serviced and overhauled. And we have the injector pump down there.
That's been sorted. Just need the head now. And a new W. First job here. We got the new batteries. So, we got to get these ones out. We got one battery disconnected on this side. We've got the bracket out that clamps it down thankfully. Usually that bolt shears off in there. And then I'll wrestle this battery up over all this. I say I built this lorry. I don't know a very very long time ago, but that's the battery isolator I would have fitted, but I don't remember doing that.
And that's been put in. And I don't I certainly didn't do that. So somebody's been in here at some point in [clears throat] its life since I built it.
>> Right. Well, we have got a drain here somewhere. I don't know why yet.
We got everything on the dead side of that. The top one is the power from the battery. The bottom one is out. So, we need to check that is actually shutting on and off as it should do. Need to check this one. But when you if it is all disconnected, we have a spark, which we shouldn't have cuz that should be technically dead at the moment. No power going anywhere. Well, after much scratching of head and got two wires on the terminal here, which that's on the negative post, which goes out of this isolator, which is dead. But this wire here We have sparks. Now that wire goes to this here.
Battery charger thing. 24 volt. It's connected. [clears throat] I pull that apart.
On right. Disconnect it.
Now we try it.
Nothing.
I think that has a dead short in it.
What else do we do these things? We give it the sniff test.
Smells a bit burnt.
Problem solved. Make sure we have ignition lights and it starts.
Lovely job. We just after we got the wiring done on the brake light switch and the solenoid down there for the starter. Let's We got the battery connected. Let's go and see what's happening in the car.
Let's turn those on. Oh, we have dash lights.
That's something. It's a star actually.
[clears throat] That's a side lightss. Side lights. Low beam. I wonder if we got the headlights working at the front. Let's go and have a look. Shall we? Get out from under the plastic.
Oh, look. So, we have got some headlights working something.
Let's see if he'll flip over on the key.
See if I got me solenoid right.
Just give a little blip.
He obviously needs to be.
Yeah, that works on the key. That works.
That's the job.
Just wired up one of the back lights.
Let's turn on the work lights.
Look at that. We have a work light.
Let's wire the other one up. That one was working. This one didn't. through the fuse. I tested the bulb. It's fine.
Test the connection. Switch works fine.
Then I had a closer look under here and it shorted out because there was a if you can see it tiny little split in the um plastic. So, we're going to have to deal with that cuz it was just dead shorting. Finally got those two sorted.
We just wired up the trailer socket on there and fixed that on. Another little bit done. We got the downpipe which has obviously been something's happened here on the end and he ain't long enough to allow to join up with the bends that go through the chassis.
We're trying to get this bit off carefully cutting down. We got nearly down through there. If we can get it off in three pieces. And we've got some um little tube here the same size which uh the uh that bit will fit on there. So we can extend it to make it the right length. Well, we re 12 in we need be long enough. Now we got it stuck on a magnet [clears throat] and we should be pretty well in line all the way through.
I'll put a few tacks weld on that and just go and offer it up and see if it looks right. A bit of fiddling and faffing later. We have to chop a a little bit out.
Just angle that down. So I think this bend here must have got so it looks a bit squished. So we just have to drop that down to make that flange fit on the manifold. And when the two bends come through the chassis look as though it's upright. So put a few more uh tacks of weld in that carefully. But this is quite thin, so we're going to have to go slow and steady. Little bit, little bit, little bit. Grind it back and make it look tidy. Cleaned up. Ground down.
Cleaned up again. And a good coat of high temperature black paint put on there. So, I'll leave that one to dry and find the bolts and things to fit that end onto the manifold. It's been a bit of faffing of farting around, but we got that in pipe on there.
Stack pipe silencer sat on there. and he's not million miles out.
So, I'm pleased with that. So, we also got water hoses on, heat cable connected up, uh water temperature sensor screwed in.
That's not a bad show. It doesn't seem as though I've done a lot today, but it's all taking time.
So, uh exhaust system in there. Just a little tinker time on this one. In there, I've got the pipe off there.
Drain the oil out. And we just got the front drive shaft off. and it fell on me. Hit me down the side of the head.
Great. So, we got those bolts undone.
You see these horrible little plates here? Somebody's welded on. So, we're going to have to lift the gearbox out with this on it cuz we can't get that plate, that bar out cuz it's been welded on. So, I need a bigger spanner. We can get those four undone off of that.
Not really want to. Well, we'll get them off anyway, but the whole lot's going to come out cuz that's welded on there and over there. Uh, yeah, nice and dirty as you can see to this air thing. I've been able to get a new trigger and a new safety switch for it surprisingly.
So, uh, hopefully we can get it back.
Oh, dropped the nut. So, we can get it back working properly again. Well folks, it is Tuesday morning.
After a few horse duties and a little bit of paperwork for government rubbish stuff, I just got down and got busy.
Engine sorted, cleaned with an inch of its life and primed up. [sighs] And we've got the front drive shaft and the rear drive shafts all primed up. Take a bit of time. I just got on with it. So, I didn't video any of it because I was just getting on with stuff. So, they're done and that's done. Hopefully get this in great turned out too bad.
[clears throat] Looking uh not too shabby, I might say. So, time for a drink cuz I'm rather parched. And um [clears throat] that's dry enough. We'll get the old gray paint mixed up and get her covered in gray. Then we put some new engine mounts in. Stick it back on the stand. Cover it up. While I'm waiting for paint to dry [clears throat] or primer to dry. We got farmer Sam here this morning. He's getting the glass out that cab. I just got h pipes disconnected off of here. Fittings out.
So, uh won't be too far. Got the hoses out that went through here. Uh we won't be too far off ready for lifting said gearbox out the way. And um yeah. So, we got two bolts down there to find which are rather covered in dirt.
And then um yeah, so we got that disconnected.
There's one bolt. You can come out ready to get this out. Then we got oil in that tank to get drained out before we can take it out. There's our straightforward. We got that one out eventually. That one down there. It's got two nuts on it. They're lock solid.
There's not enough room to get a grinder in there. I got the spanner stuck on the back of it now. It's turning, but we're going to come up with plan B.
And then the front's unbolted, ready to come out. So, we'll uh have a move round and drag this lot out. [clears throat] Put the frame on it. We can undo one there and one there. And take the whole bracket out. Three coats of paint on that one. Looking good. And we've done uh the drive shafts here as well. They're all done now. Leave them to dry.
Progress out here. He's just showed his first bolt off. [laughter] We got all them out. That window frame's out. That one's out. Uh back one's out.
So all the glass is gone. Good progress.
Clutch run off. I was expecting this to be seized up, but surprisingly it's not.
The same with that end. It's a bargain.
Didn't expect that one. Like I say, you're always one bolt away from great come apart. Oh, we got an issue like the one on the back of the gearbox, but that's uh made up for that little bit.
>> There's the heater box out. Wipe motor out.
Getting through it. Obviously, somebody's been in here before. Some dodgy wiring there.
That needs uh that needs sorting out.
Some years ago, I put a new hinge on that back window. So, we've only got these two to do. Let's pack some of this stuff on a pallet out the way for now.
Is this steering wheel going to come off?
It's going to go round and round.
Oh, look at that bit of force with the yoga dugger. Surprise. Those massive great long screws in there, which rather excessive. Managed to get them undone.
So, that's that bit loose. And just looking down here, what we got here? We have a screwdriver holding the clutch pin in place.
Don't see that every day.
Yeah. Well, this is uh near enough dry.
We can bunk some new engine mounts in there. [clears throat] Stick it back on the frame. Out the way.
[clears throat] One dashboard extracted.
Looking a bit bare in here now.
It's coming out. Had a move around. Move that over there. We drag this one out forwards enough to be I get forklift over the top to extract that there gearbox which I think is going to be a job for tomorrow cuz it's been a busy old day. What a day folks. Anyway, that's looking good.
Those looking good. Notice that's come apart. We got that apart. Been busy.
Time to go and do a bit of paperwork and have a beer. So, as always, thanks for watching. Click the old like, subscribe, give me a thumbs up, drop me a comment, hit the like button. That'd be much appreciated. And uh yeah, progress all in. So, until next time. Catch you later. I'm out of here.
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