I have just finished reassembling the 109 after tinkering again with the gearbox. I’m hoping that I have found the cause of the 4th gear jumping out on the over-run. It seems like the position that I had set the selector fork on the shaft was too far forward, and this was preventing the shaft from sliding far enough forward for the detent ball to engage in the shaft’s rear most (4th gear) groove. I have yet to test run the work, but I’ll be taking it to work tomorrow, so we’ll see what happens.
The brackets for the pioneer tools are getting a cycle in the dishwasher to degrease and weather them before etch priming and painting. I have found that etch priming straight on to newly passivated steel doesn’t work well, and these brackets will need good paint adhesion.
The new cargo rails arrived. I will be fitting a length to the outer corner of each wheel arch (which will entail some trimming around the fuel tank filler neck and the seat belt brackets). The lower rails will either run on the floor as shown in the photos or rotated 90 degrees and fitted to the wheel arch sides (they can’t be bolted to the floor in the corners because of the bolts securing the floor panel to the under-side steel braces).
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