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Old 6th June 2016, 22:23   #11
Amsca2
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At least you'll have better weather than I had in sunny scotland when I done mine.
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Old 7th June 2016, 06:49   #12
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Quote:
Originally Posted by Daveluck View Post
Ah, yes of course drive shafts I'll syringe first.

I had a look earlier but couldn't see anything. Really not looking forward to this little job...
Yes,the syringe trick is the best option (no need to empty completely however)
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Old 8th June 2016, 17:02   #13
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Right then!

New DMF required.

I have a good 40mm play before I hit resistance then another 10 or so either end. The front wheel / plate also rocks, a good 1-2 mm. Also it rotates catches and if you back off slightly it moves on again. I think it was on its way out and my juddering halt in 4th just finished it off.

Burn/ heat marks on the clutch plate and the dmf.

The clutch has only done 21k kms but the friction plate looks like its been to the moon and back while riding the clutch. Less than .5mm before the rivets. can only assume filing dmf has hastened the wear.

Slave looks like new but replacing anyways. Given the friction plate is unbranded ( as is the slave ) I've just ordered luk.

Also ordered new bolts for sub frame, dmf and clutch plate. Just waitingmformthe stuff to arrive.

What an absolute pig of a job. I just couldn't get the transmission over and ended up dropping the sub frame completely.

The steering rack bolts were not 85 newtons! I honestly thought I would have to try and put it all back together and drive it to the local grease monkey. Slept on it and cracked them this morning. Needed a windy gun on 2 of them.

2 of the 6 clutch plate bolts had been mashed. I guess by the same inept who destroyed the transmission plug. And the others are damaged. A real struggle getting them off.

I'm dreading putting it all back together....

Mike, your idea of the support bar across the mount was inspired. Got me out of trouble today and the box is currently supported by this.

Any tips on how to put this back together again?

You have got to admire the likes of Andy Willi, doing just this one will be enough for me. I couldn't face making a living out of it.
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Old 8th June 2016, 17:36   #14
FrenchMike
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It's recommanded to make the aligment easier to put the positioning dowel on the box

Check for any oïl leak on both sides..

Congrats and good luck for the rest .(take your time)

Mike
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Old 17th June 2016, 13:31   #15
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All the parts have now arrived. Other commitments pending I'll start putting it back together this weekend.

The difference between the 2 flywheels is immense. I can just about get a little play between the 2 wheels and absolutely no rocking.
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Old 17th June 2016, 23:37   #16
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Dmf on so is the clutch plate and friction disc. Slave greased and fitted.

Struggling with the gearbox and have called it a night. Start again tomorrow but Ill need to have the Mrs underneath the car aligning the prop shaft etc. Have a horrible feeling that this is going to be a right pig.
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Old 18th June 2016, 06:36   #17
FrenchMike
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Quote:
Originally Posted by Daveluck View Post
Dmf on so is the clutch plate and friction disc. Slave greased and fitted.

Struggling with the gearbox and have called it a night. Start again tomorrow but Ill need to have the Mrs underneath the car aligning the prop shaft etc. Have a horrible feeling that this is going to be a right pig.
The only difficulty is getting the aligment while you have to rotate the box of 45 deg.

These little Tools help a lot (without assistant)



Mike
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Old 18th June 2016, 15:19   #18
Daveluck
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Gearbox is on!

Tried everything, even had the Mrs underneath helping to line it up. No joy.

After a rather tense cup of coffee together I decided I'd call it a day. Started clearing up and then cursed myself for a quitter.

Climbed underneath, ( a very tight squeeze) grabbed the box and lifted and twisted....was rewarded with a very pleasant sound of cover meeting engine block. Then got the Mrs to just slip in 1 bolt while I squeezed myself out again.

Will now spend the rest of the day putting it back together. Tomorrow I'll refill the transmission and hopefully take it for a short drive.

And I managed to get the shower room plumbing done!
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Old 18th June 2016, 16:59   #19
FrenchMike
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Quote:
Originally Posted by Daveluck View Post
Gearbox is on!

Tried everything, even had the Mrs underneath helping to line it up. No joy.

After a rather tense cup of coffee together I decided I'd call it a day. Started clearing up and then cursed myself for a quitter.

Climbed underneath, ( a very tight squeeze) grabbed the box and lifted and twisted....was rewarded with a very pleasant sound of cover meeting engine block. Then got the Mrs to just slip in 1 bolt while I squeezed myself out again.

Will now spend the rest of the day putting it back together. Tomorrow I'll refill the transmission and hopefully take it for a short drive.

And I managed to get the shower room plumbing done!
Congrats with my advice take your time in order to forget nothing
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