Fitting Instructins REMOTE GREASING KIT FOR MORGANS SERIES 2 Thank yu fr purchasing a Remte Greasing Kit fr yur Mrgan. These fitting instructins shuld enable yu t fit the kit t yur Mrgan. Depending n which mdel Mrgan yu have, fitting will take frm 2 t 4 hurs. If yu have any prblems fllwing these instructins please dn t hesitate t email me at geff@mpscnsult.cm r telephne me n 61-2-45677247 (nly during Australian business hurs please). Yur kit cntains: Geff Williams 2 x pre-assembled billet aluminium grease blcks fr munting n inner guard in engine bay 4 x stainless M6 cuntersunk allen head screws with washers and nuts 2 x 90 swivel elbws1/8bsp t 6mm push-n (replace tp grease fitting) 2 x 90 swivel elbws M6 t 6mm push-n (replace lwer grease fitting) 2m f 6mm high pressure Nyln tube 1m f insulatin sleeve (V6 Radsters nly) Template fr munting f grease blcks n inner guards www.geffsshed.net
Tls Needed: Paint pen r crayn fr marking drill hle lcatins n inner guard 4mm Hex key fr tightening stainless screws which hld grease blck t inner guard 10mm, 11mm & 13mm spanners Utility knife fr cutting nyln tubing - use new blade Permatex ultra grey r similar high quality gasket maker fr sealing thread f lwer grease fitting Grease gun and grease Pwer drill - the mre cmpact the better. 7mm drill bit Die grinder r Dremmel with tungsten bur (nly fr lder cars withut lwer spring bearing fitted - refer instructins) 16mm Tungsten hle cutter. Car jack r hist if available Axle stands (if using car jack) If using a jack, raise the vehicle as high as yu can and ensure it is safely supprted by car stands. www.geffsshed.net
Intrductin: Regular greasing f the kingpins is an essential part f Mrgan maintenance. Never a fun jb, it has been made even mre nerus with the newer cars requiring the frnt wheels t be remved fr accessing the tp kingpin greasing pint every 1600km (1000miles). This remte grease system is designed t enable yu t grease the tp and bttm f the Mrgan frnt suspensin kingpins withut having t either remve the rad wheel r lie under the car. All the fittings are f prfessinal quality and feature push-in capture f the nyln tube rather than the cumbersme lives used in cheaper systems. The tubes can be easily remved and reinserted multiple times. The tp and bttm kingpin fittings are f swivel design, allwing full suspensin and steering travel withut stress n the tubing. These kits successfully perated n three Mrgans travelling arund Australia in 2013 - a 1995 4/4, a 1978 Plus 8 and a 2012 Radster. A ttal f 60,000km between them. PLEASE NOTE THAT ALL INSTALLATION PHOTOS IN THIS DOCUMENT SHOW THE EARLIER GREASE BLOCK. THE NEW VERSION IS MORE COMPACT AND CAN BE MORE EASILY FITTED IN TIGHT SPOTS. Layut f fittings: The grease blcks are attached t the engine side f the inner guards n each side f the car. Each grease blck has tw nipples n the tp and tw utlets. The utlets exit thrugh the inner guard and are cnnected t the 6mm nyln tubing. One ges t the tp grease pint, the ther t the lwer grease pint. Layut f remte greasing system www.geffsshed.net
Instructins: Step 1: Raise car and remve frnt wheels. Supprt the car with stands. Step 2: Installing the grease blcks. The grease blcks are installed just belw the lip n the engine side f the inner guards. The actual external dimensins f the blcks are 66mm x 25mm. They can be lcated anywhere between the frnt r rear f the engine cmpartment but the clser t the frnt the better as this mves them away frm engine exhaust heat. Use a template t find an ideal lcatin. Make sure there is clear space n the utside f the inner guard t allw drilling and ruting f tubes. The grease blcks can be ffset, i.e. in different lcatins n each side f the car. Lcatin in an lder 4/4 On late V6 radsters the blcks may need t be lcated just abve where the exhausts exit. In this case thermal sleeving is required. Once yu have chsen yur preferred lcatin, use the template t mark where the hles will need t be drilled in the inner guard. It is helpful t place sme masking tape ver the area and use a pen t mark the hles.lightly centre punch the hles t help with drilling. Lcatin in a late V6 Radster The exit hles fr the grease utlets are 16mm in diameter and are best made using a tungsten hle cutter these are available quite cheaply nline. The hles fr the M6 screws are 7mm. Deburr the hles, check fr fit and adjust hles if necessary and then attach the grease blcks using a hex key and 10mm spanner. Exit lcatin n an lder 4/4 Dimensins f the grease blcks Exit lcatin in a '75 Plus 8 Please nte: The aluminium grease blcks are sealed and maintenance free. If yu ever remve the grease nipples please d nt vertighten when refitting. The 1/8 BSP fitting is a very fine thread and can be stripped if vertightened. www.geffsshed.net
Step 3: Installing the tp and bttm grease line adapters Tp Adapters: Remve the factry fitted grease nipple and replace with the supplied 90 1/8 BSP adapter. Lwer adapters: If yu have a late mdel car r an lder car with a factry r Mulberry lwer bearing upgrade skip t the next step. Older cars withut lwer bearings upgrade: T allw the prper mvement f the grease adapter and tube under full steering lck it is necessary t sculpture the brnze thrust plate underneath the spring. This can be dne n the car but requires a dye grinder r Dremmel t remve the material. A tungsten carbide bur is needed. The re-prfiled brnze thrust plate Next: Remve the factry fitted grease nipple and replace with the supplied 90 M6 adapter. The thread n the ld grease nipple is 1/4 BSF whereas the thread n the new fitting is M6 which, althugh nt identical, gives a gd fit. As a precautin clean the threads and smear sme gd quality gasket maker n the adapter thread befre screwing it hme. Be careful nt t crss the thread and d nt vertighten. Because the new fitting can swivel it is pssible t screw it in withut having t remve the shck absrber by hlding the swivel end and using a spanner t turn the thread end but if yu find it awkward by all means withdraw the lwer shck munt. www.geffsshed.net
Step 4: Installing the tubing at grease blck Tubing t tp grease pint: Cut lng enugh t give a slight bw when fitted. Tubing t lwer grease pint: Cut tubing lng enugh t give sufficient mvement when the steering is turned lckt-lck. Better t cut it t lng than t shrt. The tubing is nrmally ruted t the rear f the tp crss member and tensin rd. Make sure yu cut the tubing cleanly at 90 with a sharp knife. Tp tube 4/4 Push the tubing in firmly at the grease blck end. Yu will feel a definite mvement f abut 6mm if it is in prperly. If nt, it will leak grease when primed but it is easily remved by pushing in the brass cllar and can be inserted again until it is crrect. Once in prperly it will nt leak as it is capable f withstanding very high pressures. If yu need extra nyln tubing it can be purchased frm any quality hydraulics supply cmpany such as Pirtek. Lwer tube lder 4/4 If yur grease blcks are in the prximity f the exhaust then cver with a length f 16mm diameter heat shield befre priming. Step 5: Priming the grease lines Once the tubing has been installed at the grease blcks the tubes need t be filled with grease. Attach the grease gun t ne f the nipples n the grease blck and pump until grease exits the end f the tube. Check t make sure grease has nt seeped ut frm the grease blck end f the tubes. If it has refit the tube (see abve). Repeat fr the ther three grease tubes. As with step 4 abve, push the tubing in firmly at the suspensin end. Yu will feel a definite mvement f abut 6mm if it is in prperly. If nt, it will leak grease when the grease gun is used but it is easily remved by pushing in the brass cllar and can be inserted again until it is crrect. Once in prperly it will nt leak as it is capable f withstanding very high pressures (ver 1000psi). Repeat fr the ther three fittings. Heat shield sleeve arund nyln tube n a Radster Lwer grease pint n a Radster Step 6: Final grease pressure test Use yur grease gun t push grease thrugh each f the fur grease blck nipples. Inspect bth ends f each tube fr any leakages and re-insert tubes if necessary. If all is gd then re-fit wheels and lwer the car. Frm nw n yu can use the nipples n the grease blcks t grease yur frnt suspensin at recmmended intervals. www.geffsshed.net 16mm heat shield may be needed n sme vehicles