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1971 Series IIa 88" Overhaul

SeriesG

Offroader
I recently acquired a Land Rover series IIa 88 for this winter's garage project. I've been wanting another one ever since I sold my beloved 65' IIa 88" some thirty-odd years ago. They were rare as hens teeth here in western Canada back then and it isn't any better now. Those that do pop up for sale are often either very expensive or very rough and all are certainly a great distance away. When this Poppy Red beauty showed up for sale at a reasonable price near Cold Lake, Alberta it was a no brainer to quickly rent a truck and trailer and make the 900km roundtrip to get it. Score!!

The short version of my "plan" is to get running, shake it down, then give it what it needs to be a mechanically reliable daily driver and weekend warrior for next summer. After a season of backcountry exploration, camping, and adventure in northern Saskatchewan it'll be ready for a complete teardown over the next winter to address chassis, suspension, and maybe paint.

A bit about the vehicle:
From the chassis number it appears to be a very late production series IIa from 1971 and just before the line changed over to the series III. It's got a 2.25L petrol engine, suffix F IIa transmission, alternator, powered dual-circuit brakes, headlamps in the wings, side marker lights, reverse light, and a fancy interior package including comfy (comparatively) seats, full coverage door panels with arm rests, and a complete headliner and interior trim panel package including seat belts. It's pretty luxurious compared to my old bare-bones 65!
Upon initial inspection the frame seems to be surprisingly rust free and solid. The odometer says 18437 miles so I'd guess it's got that plus 100,000. It's leaking oil from every possible place and more which is to be expected of a vehicle that's over fifty years old and probably hasn't been driven in thirty. It comes with the 1977 version of the famous Warn 8274 winch, a Toro type overdrive unit, and what the previous owner claimed were 16 x 6" Defender wheels. From what I can tell it's got all the series III parts a IIa can have and still be a IIa.

As for myself I'm a Machinist by trade and after 35 years in the business I'm on the management end of a medium sized manufacturing facility. I've always had a love for bringing rusty mechanical marvels of the past back to working order and I've done a slew of vintage cars, trucks, tractors, stationary engines, etc over the years. I'm very excited to get this fine 4x4 back on the dirt.

So here we go. These are the initial pictures I took after we brought it home. It did come with the fenders and bonnet but they had been removed by the previous owner for engine work I suppose. Enjoy!
 

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I recently acquired a Land Rover series IIa 88 for this winter's garage project. I've been wanting another one ever since I sold my beloved 65' IIa 88" some thirty-odd years ago. They were rare as hens teeth here in western Canada back then and it isn't any better now. Those that do pop up for sale are often either very expensive or very rough and all are certainly a great distance away. When this Poppy Red beauty showed up for sale at a reasonable price near Cold Lake, Alberta it was a no brainer to quickly rent a truck and trailer and make the 900km roundtrip to get it. Score!!

The short version of my "plan" is to get running, shake it down, then give it what it needs to be a mechanically reliable daily driver and weekend warrior for next summer. After a season of backcountry exploration, camping, and adventure in northern Saskatchewan it'll be ready for a complete teardown over the next winter to address chassis, suspension, and maybe paint.

A bit about the vehicle:
From the chassis number it appears to be a very late production series IIa from 1971 and just before the line changed over to the series III. It's got a 2.25L petrol engine, suffix F IIa transmission, alternator, powered dual-circuit brakes, headlamps in the wings, side marker lights, reverse light, and a fancy interior package including comfy (comparatively) seats, full coverage door panels with arm rests, and a complete headliner and interior trim panel package including seat belts. It's pretty luxurious compared to my old bare-bones 65!
Upon initial inspection the frame seems to be surprisingly rust free and solid. The odometer says 18437 miles so I'd guess it's got that plus 100,000. It's leaking oil from every possible place and more which is to be expected of a vehicle that's over fifty years old and probably hasn't been driven in thirty. It comes with the 1977 version of the famous Warn 8274 winch, a Toro type overdrive unit, and what the previous owner claimed were 16 x 6" Defender wheels. From what I can tell it's got all the series III parts a IIa can have and still be a IIa.

As for myself I'm a Machinist by trade and after 35 years in the business I'm on the management end of a medium sized manufacturing facility. I've always had a love for bringing rusty mechanical marvels of the past back to working order and I've done a slew of vintage cars, trucks, tractors, stationary engines, etc over the years. I'm very excited to get this fine 4x4 back on the dirt.

So here we go. These are the initial pictures I took after we brought it home. It did come with the fenders and bonnet but they had been removed by the previous owner for engine work I suppose. Enjoy!
Like that, looks like a good base to start from too. Good luck with it all and post the updates.
 
Series perfection.
Or very close to it.
I must say that I really like the Poppy Red paint scheme.
Might go for it myself yet
I wasn't sold on the red color at first but it's quickly growing on me. It seems to be a somewhat uncommon color for a Land Rover which is cool. At least it isn't a bunch of different colors and shows an acceptable level of "patina". I'm not in any hurry to paint it as where I'm going to drive it it's going to get scratched up anyway.
 
The only condition my wife put on my doing this project is that I hold off on spending a bunch of money on it until after Christmas. Fair enough. There is lot of work to do before new parts can go on anyway, such as cleaning. Yes cleaning. Scraping, scrubbing, washing, soaking, more scrubbing, more scraping... you've all been there. It's got to get clean before I can properly work on it and assess the maintenance it will need.

Once I got it into the garage and warm the first order of business became apparent: de-stink the interior. Years of sitting outdoors with has given it a pungent mildew stank that has to go. I removed the seats, door panels, and rear benches and put them out in the shed. Long ago a previous owner thought gluing indoor/outdoor carpet and some kind of foam insulation all over the interior was a good idea. Man what a mess! The carpet came off fairly easily but left behind decades old thickly applied contact cement all over each panel. The foam insulation is also glued into every nook and cranny and is now a crumbly gooey mess that resembles cotton candy but smells far worse. A combination of 3M General Purpose Adhesve Cleaner spray, pro-strength "Goof Off", and lacquer thinner is doing the trick of removing all the crap but it's a lot of labour and toxic fumes.
 

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With all of the "carpet" and upholstery out and a lot of the glue taken off it smells much better. Maybe "doesn't smell as bad" would be a better way of putting it. It doesn't smell like anything other than, well, whatever - it doesn't smell anymore. Good enough.

To break up the monotony of donning mask and glove to use the nasty glue removers I decided the door tops need to come off so I started with the left hand door. I knew it would be a struggle and it was. I guessed they'd never been off and my guess proved correct as when I finally after two days of penetrating oil and careful pounding with a 2lb hammer got the thing off there was what I imagine is original factory grease pencil markings on the galvanized door top. Neat! I dig that kind of thing.

I had so much fun getting the left door top off that I decided to do the right later and just pulled off all the doors instead. Maybe soaking the studs with penetrating oil when the door is upside down will work better. We shall see...
 

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I think, being a 2a, that red might be Masai red. My 2a was that colour under all the other colours....😏 Mine was ex post office.

It's going to be a good project to follow, look forward to seeing how your 'no money spent before Christmas ' goes....🤣
Hmmm... Masai Red - I like it! It's much more "Marlin Perkins" than Poppy Red. Haha!
 
With the interior mostly cleaned up I thought I'd remove the floor plates so I could have a look at the transmission and transfer case. The vehicle came to me with the clutch pedal assembly removed so I know it needs work in that area so removing the floor will give me better access to the clutch slave cylinder as well. Also the transmission doesn't seem to want to shift into 3rd or 4th so that's a thing too.
Of course I had to drill out most of the screws and bolts but I won and the plates came off in the end. After much scraping and washing the transmission looks much better and will be easier to work on. The shifter is very sloppy and has been cut off shorter which I don't like so I'll address that next.
 

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Great progress @SeriesG . Such a good idea to get the cleaning done now , it will make future work much easier.

To reduce the drumming of the panels on my series 3 I’ve used roof flashing tape . No need to cover the whole panel just a good sized square / oblong will help quite a bit .

Keep the updates coming , I’m enjoying reading them 👍
 
The shortened shifter was bugging me enough that I decided to just get it over with and fix it. From what I can gather there was once some kind of plastic ball thingy on the transmission end of the shifter where it meets the shifter fork rods but it's long gone now leaving a sloppy shift and metal-on-metal action. I searched around online and didn't find a suitable part I could purchase so I fired up the lathe and made a brass ball with a 1/2NF thread inside it. I then attempted to thread the end of the shifter shaft and found it too hard to run a die over. Not to be deterred I ground it's diameter down and finally got a bit of thread on it although I ruined my die. Oh well...
I affixed the ball to the end of the shifter with red Loctite and moved on to restoring the correct length and bend.

I don't have the exact dimensions of the shifter rod so I compared mine to pictures I found online of unadulterated ones. From there I had a professional welder coworker weld on a piece of 1/2 CR steel (thanks Trent!) and dressed it down with a file until it measured as original. I then heated and bent the lengthened piece and cut it off to match as closely as I could to what I saw in pictures of originals. With a tiny bit of Bondo to fill imperfections where it was welded it I painted it and pressed the knob back on. I'm very happy with the results although it seems a bit too long. Think I'll lop a couple of inches off and see what that looks like.
 

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Good job.
Not had to go that far into my current project yest as it seems to be mostly service items and general tidy up.
Most parts are available here too next day or so delivery. Anything that needs making is generally modification stuff to make ease of use.
Got a front bumper to make up so a winch can be discretely tucked in behind the grill but I think Incan just buy one .
Anyway keep it up, at this rate you will be painting in the spring....😎👍🏿
 
Getting the shifter fixed didn't solve my problem of not shifting into 3rd/4th. I tried everything I could think of but I just couldn't get it into those gears. I figured I'd better remove the top of the shifter housing on the transmission to see if I could spot any obvious problems and found I couldn't do that without removing the seat box. If it just had another 1/4" of room I might have done it. Okay then fine... I'll remove the seat box.

I removed the fasteners that would move and drilled out the rest which was at least half of them. The lower seat belt anchors were the worst. Drilling the heads off the bolts proved to be much easier and faster than struggling with wrenches to save $5 worth of fasteners. Finally the seat box came out and I could see the whole transmission setup and get the gearbox top off. That ended up not proving anything so it appears I'll have to remove the gearbox(s) entirely and tear them down to find the problem. I was hoping not to have to do this at this early juncture but it is what it is so I might as well get at it. Actually, it's probably the right thing to do as I want to go through the overdrive anyway and the 4wd doesn't engage so that needs looking at too, and the mounts are bad as well. Gee... that's quite a list of "bad" when you combine it with the 3/4 shift problem. This should prove to be an interesting start to the real work.
Luckily I found an almost-new hydraulic engine hoist on a local buy-n-sell website for $200 so I'll pick that up tomorrow.

What is it about struggling with a rusty and worn out 50 year old piece of junk that is so much fun? Maybe I'm in the Honeymoon Phase or something but I'm really enjoying this! 😁

(On second thought it's likely because I haven't had to spend any real money yet... haha!)
 

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