Outer Limits 4x4 Board

Late last year i finally finished replacing the chassis in my feroza. Bloody HUGE job.

The front mount of the rear leaf spring tore out of the chassis. It had rusted from the inside and finaly let go.
I bought the Roza new in October 1995 and after every beach/ mud run i have always spent a few hous under it hosing everything clean.
But apparently not well enough. The other side was heading that way too.

Gunna post some pics of the job.


Bracket Torn Away from Chassis.




Found a 2nd hand chassis. After a measure up to make sure all was square and a thickness check around the leafspring mounts etc. i bought it for $100.




Cleaned it all up and painted it ready to start putting bits on.

That paint makes it look bling

The plan was to disconnect everything between the body and the chassis.
Jack the body up, roll the chassis etc out from under the body.
Swap everything to the new chassis, then roll her back under.
Drop the body down again and hook everything back up.
Sounds easy if you say it quick.

I pulled the engine out first cause i didn't think i would be able to lift the body up high enough to clear it.

I'm impressed - you did it all in your backyard!?!

Nice work. I am waiting details of what to take care when refeating a new chassis. NICE WORK AGAIN

Also chech out other stuff that are on the engine or on the body that might need any changes or repairs.

murcod wrote:I'm impressed - you did it all in your backyard!?!

Yeah did it all in the back yard. Only had a garden shed to put all my tools.

ferozamaniac wrote:Also chech out other stuff that are on the engine or on the body that might need any changes or repairs.

It's all finished and has been bck on the road now for about 7 Months. I replaced HEAPS of stuff while i was going. Mainly because it was a lot easier to get to while it was all apart and it would have needed doing at some point anyway.

Up she goes. Jacked it up with a bottle jack on one side and a trolly jack on the other site. Just went bit by bit using blocks of timber.

Ha haha is like fitting a bodylift . Anyway your yaurd is perfect for you ROZA. Would you recomend it for other people to change the chassis by themselfe?

ferozamaniac wrote:Ha haha is like fitting a bodylift . Anyway your yaurd is perfect for you ROZA. Would you recomend it for other people to change the chassis by themselfe?

I wouldn't recommed it unless u have some mechanical knowledge and a few mates to give you a hand. It's not something you would do unless you had to.

And out she comes.....










I made some stands out of 50x50x6 box section (about $200 in steel).
I wanted to make sure it was solid. Didn't want it falling down.
They support the body at the points where it bolts to the chassis

Motor and gearbox onto the new chassis.



Rear axle assembly.


Later on i pulled the rear axle back out and made some mods to the spring mounts. They tend to collect sand and mud in them so i welded some plates over them to seal them up. I didn't take any pics of the finished job but I can if anyone is interested.

Easy to change the oil and filter in that last pic

Good pics mate

and swapped all the front end suspension components.







I left the power steering circuit entact so i didn't have to worry about getting air in the system and having to bleed it all etc. Just swapped the whole thing without disconnecting any of the piping etc. You can see it all lying on the ground in the second pic.

Did the same with the aircon, disconnected the compressor from the engine and left it attached to the body.

nice pictures. Was it hard to refeet again the front system IFS?

No it wasn't too difficult, just unbolt and bolt back on.
It did have quite a bit of positive camber on it once it was all finished. I did keep all the shims in there same location when i swapped over, but it was still out. I think it was beacause of the slight differences in the chassis where the front swingarms bolt on.

Got a wheel alignment done once it was all back together and all is good again.

I pulled the rear flares off and found rust on both sides. Sand had built up in between the panel and the flare and retained moisture. I recommend others check this spot for rust.


Also reinstated the strap around the LHS engine mount. This stops it from pulling apart under hi torque loads.
This is a common problem with Ferozas as you are all probably aware.



Also replace the following items while everything was easy to get to;
- Timing belt, tensioner and camshaft seal,
- Other fan belts
- all heater hoses, there are some tricky ones that would be a PITA to change normally. ie below dizzy and under inlet manifold.
- Steering idler arm (Bushes were stuffed)
- fuel level sender
- dip stick tube (was leaking around the bottom and was kinked in a few places from the &^%$ who put the extractors on)
- steel brake line from engine bay to rear breaks. (The ONLY thing i forgot to disconnect)
- Plugs and leads
- Shocks
- Diff breathers
- Diff pinion seals and grb prop shaft seals.
- Wheel bearings
- All oils and filters
- O2 sensor
- Battery & alternator (both were stuffed)
- and a new set of 5 BFG Muddies.

quite a few $ all up, but i figured it's worth the peace of mind when your out bush.

heaps of work - well done.......

put a strap around the transmission mount as well otherwise that will
break on you.

Dam mouints - none ot them are up to the job, and they arn't cheap.

MightyMouse wrote:heaps of work - well done.......

put a strap around the transmission mount as well otherwise that will
break on you.

Dam mouints - none ot them are up to the job, and they arn't cheap.

I have never had a problem with the transmission one. I did replace it a number of years ago just cause i was doin the others, but ot wasn,t broken.

They are pretty crappy. I was on my 6th one before i put the stap around it. It's been good for about 4 years now.

Dropping the body back down.









Was bit of an effort to get it down and lined up again but it worked out in the end.

hi clint, awesome work.
glad you finaly got around to getting it all going again.

Thanks mate.

Here are the pics of the old chassis cut up and ready to go to the dump.




I collected about a 2 litre milk bottle full of rust flakes that fell out of the inside of the chassis.

I made this work bench out of the stands i made to hold the body up.
It's bloody heavy.