Rover 416 GTI Auto - Restoring an old friend
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Montegoman
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Re: Rover 416 GTI Auto - Restoring an old friend
Great update. Keep them coming.
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214GSi G79XKV (R8 No.1) (9 yrs of ownership)
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75 2.5 Connoisseur SE Tourer (20 yrs of ownership)
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Re: Rover 416 GTI Auto - Restoring an old friend
New Drop Links and Steering Ball Joints fitted without too much fuss.

Just need to make sure the rear compensator arm bolts can be loosened before I take it to get the tracking done , which hasn't been done for at least 20 years
Next job is to replace the front roll bar rubbers with some poly bushes.
Just waiting for the penetrating oil to do its work on the bolts, which seem to be a bit tighter than the quoted 15Nm.

Just need to make sure the rear compensator arm bolts can be loosened before I take it to get the tracking done , which hasn't been done for at least 20 years
Next job is to replace the front roll bar rubbers with some poly bushes.
Just waiting for the penetrating oil to do its work on the bolts, which seem to be a bit tighter than the quoted 15Nm.
1991 Rover 416 GTi Auto - Flame Red - Owned since Aug 97 
Re: Rover 416 GTI Auto - Restoring an old friend
Well if you’d read one of my other posts you will have read that whilst in the process of fitting new front roll bar bushes one of the captive nuts inside the rear front subframe/beam , which secures the roll bar clamp to the sub frame , has broken free.
Will take it to a garage I have previously used to see if it can be repaired easily or if the subframe/beam needs to be removed and refurbished.
I thought this was going to be the last quick job of the winter before getting the tracking sorted and a trip to POL
Will take it to a garage I have previously used to see if it can be repaired easily or if the subframe/beam needs to be removed and refurbished.
I thought this was going to be the last quick job of the winter before getting the tracking sorted and a trip to POL
1991 Rover 416 GTi Auto - Flame Red - Owned since Aug 97 
Re: Rover 416 GTI Auto - Restoring an old friend
Keep at it sometime you go back to go forward and if its rotten better find out now than on the road ps I have front for honda but rear not at the moment all the best hope it a easy fix and that another place to inject oil/wax which ever floats ye boats 
Re: Rover 416 GTI Auto - Restoring an old friend
Thanks.
Yes in a way I’m glad it’s gone now even if I’m a bit disappointed not to get the bushes fitted.
The bolt on this hole was actually was very easy to move , unlike some of the others, so clearly the captive nut was very much on it’s last legs.
We’ll see what the garage makes of it, their speciality is Triumph Stags but they seem to be happy to take on other work.
I might be interested in a replacement front one as I painted over the current one with hammerite a few years ago as it was going rusty, but every time I look at it I think what a mess it is. I need to do it properly job particularly in the recess where the brake reaction bar bushes fit .
Yes in a way I’m glad it’s gone now even if I’m a bit disappointed not to get the bushes fitted.
The bolt on this hole was actually was very easy to move , unlike some of the others, so clearly the captive nut was very much on it’s last legs.
We’ll see what the garage makes of it, their speciality is Triumph Stags but they seem to be happy to take on other work.
I might be interested in a replacement front one as I painted over the current one with hammerite a few years ago as it was going rusty, but every time I look at it I think what a mess it is. I need to do it properly job particularly in the recess where the brake reaction bar bushes fit .
1991 Rover 416 GTi Auto - Flame Red - Owned since Aug 97 
Re: Rover 416 GTI Auto - Restoring an old friend
Just come back from blasting/ coating can be posted pm if you what it
Re: Rover 416 GTI Auto - Restoring an old friend
Just a quick update.
Well beginning to see a picture now having viewed the cross beam whilst the car was on the garage lift.
I recall having some welding done on the rear front cross beam many years ago. In fact looking at my records it was in 2002.
I then have a further invoice for the some welding done in 2016.
The view was it was not a particularly good weld from 2002 but it had obviously lasted a few years.
One of the repairs patches is next to if not including part of the captive nut that has come loose.

It seems likely that it was probably not treated internally when the weld was done and corrosion has creep under the captive nut
.
It was described as an MOT weld and considering what I paid for it it was only ever going to be a make do and mend repair.
So the plan is to cut out the existing repair and include the area around the captive nut in the repair. It's booked for the beginning of March so if it doesn't go pear shaped I will make POL this year.
Hopefully this plan will work and provide a short to medium term fix until a replacement cross member or a proper refurbishment can be sorted.
Well beginning to see a picture now having viewed the cross beam whilst the car was on the garage lift.
I recall having some welding done on the rear front cross beam many years ago. In fact looking at my records it was in 2002.
I then have a further invoice for the some welding done in 2016.
The view was it was not a particularly good weld from 2002 but it had obviously lasted a few years.
One of the repairs patches is next to if not including part of the captive nut that has come loose.

It seems likely that it was probably not treated internally when the weld was done and corrosion has creep under the captive nut
.
It was described as an MOT weld and considering what I paid for it it was only ever going to be a make do and mend repair.
So the plan is to cut out the existing repair and include the area around the captive nut in the repair. It's booked for the beginning of March so if it doesn't go pear shaped I will make POL this year.
Hopefully this plan will work and provide a short to medium term fix until a replacement cross member or a proper refurbishment can be sorted.
1991 Rover 416 GTi Auto - Flame Red - Owned since Aug 97 
Re: Rover 416 GTI Auto - Restoring an old friend
Issue with captive nut now sorted. Phew.
A bit more work/cost than anticipated - as always - but an old repair on the near side removed and replaced along with the capitve nut being refitted.
Cross member also had a repair to the off side which was cleaned up and both repairs painted , inside wax treated and a couple of holes drilled to allow me to get a lance in to inject more wax if needed.
Whilst they had the roll bar off they also fitted the new roll bar bushes and clamp bolts that I had purchased.
Before and after shots look similar but the welding looks a bit tidier.

I'm sure the work done is of good quality but for the longer term I have acquired a refurbished front cross member and hopefully I will acquire the rear one which I can store ready for fitting at a future date.
Just need to fit the new compensator links on the rear suspension and than get the tracking done so its all good for POL.
Thanks for looking
A bit more work/cost than anticipated - as always - but an old repair on the near side removed and replaced along with the capitve nut being refitted.
Cross member also had a repair to the off side which was cleaned up and both repairs painted , inside wax treated and a couple of holes drilled to allow me to get a lance in to inject more wax if needed.
Whilst they had the roll bar off they also fitted the new roll bar bushes and clamp bolts that I had purchased.
Before and after shots look similar but the welding looks a bit tidier.

I'm sure the work done is of good quality but for the longer term I have acquired a refurbished front cross member and hopefully I will acquire the rear one which I can store ready for fitting at a future date.
Just need to fit the new compensator links on the rear suspension and than get the tracking done so its all good for POL.
Thanks for looking
Last edited by Plodder on Sat Mar 28, 2026 4:58 pm, edited 1 time in total.
1991 Rover 416 GTi Auto - Flame Red - Owned since Aug 97 
Re: Rover 416 GTI Auto - Restoring an old friend
Fitted new rear compensator arms so hopefully now I can get the tracking sorted before POL. Just hoping there's not a fuel crisis by then

The first one took a bit of time as I didn't realise that you have to drop the trailing arm a bit to allow the bolt holding the compensator arm to the trailing arm to be removed. Luckily you don't have to remove the trailing arm bush bolts completely although it's probably hanging on the last 3/4 threads
Noticed the n/s trailing arm bush has started to split on the outside but doesn't seem to have progressed through the bush completely so is not visible when viewing the bush from underneath the car. Would explain why a few MOT's ago I had an advisory that the bush needed replacing but I haven't had any further comments since.
Job for the winter.
Have also now acquired both front cross members which will be replaced in the coming years along with a healthy dose of cavity wax. My thanks to Chris Taylor for finding these for me
Just checked my records and the advisory on the nearside trailing arm bush was 2016. So it's lasted quite well with a split in one side. Probably doesn't help with the handling though.

The first one took a bit of time as I didn't realise that you have to drop the trailing arm a bit to allow the bolt holding the compensator arm to the trailing arm to be removed. Luckily you don't have to remove the trailing arm bush bolts completely although it's probably hanging on the last 3/4 threads
Noticed the n/s trailing arm bush has started to split on the outside but doesn't seem to have progressed through the bush completely so is not visible when viewing the bush from underneath the car. Would explain why a few MOT's ago I had an advisory that the bush needed replacing but I haven't had any further comments since.
Job for the winter.
Have also now acquired both front cross members which will be replaced in the coming years along with a healthy dose of cavity wax. My thanks to Chris Taylor for finding these for me
Just checked my records and the advisory on the nearside trailing arm bush was 2016. So it's lasted quite well with a split in one side. Probably doesn't help with the handling though.
1991 Rover 416 GTi Auto - Flame Red - Owned since Aug 97 
Re: Rover 416 GTI Auto - Restoring an old friend
You welcome nice to meet you see you at pol when we are both not working on car *laughs* you got luck this one was a really good subframe .