[trackday_prep] Paul's Gti6

[Paul_13 212 1 Cars]

Bloody f***ing oil leak is back again!

 

Inlet is coming off so will have a good look.

 

List of what needs doing:

 

Inlet off

Find oil leak

Remove plastic vacuum tube to inlet blank off and put servo hose straight on pump.

Fit loom off Miles Thanks again

Fit bottom engine mount

Fit OE top mount

Fit OE fork bushe

Sort out L bracket gear linkage bushes

Sort out clonking noise when braking

Sort out negative camber on drivers side wheel.

Driveshafts boots

Fit 205 diff

New inlet gasket

Build up 205 beam with new bars (22mm) and 24mm ARB. Using 6 arms again

Get SL434's refurbed

New tyres

Mintex 1144 pads for 266mm brake setup

[SurGie 54]

Could you get a gasket made then use some sump sealant together, AFAIK Pug dont sell them do they ?

[Paul_13 212 1 Cars]

It's not the sump mate, it's something on the front of the block. Probably the blanking plug or a sensor.

 

Just fitted some mintex 1144 pads off of Miles for the GRD and bloody hell it stops well

[SurGie 54]

I meant gasket sealant stuff for the inlet.

[Paul_13 212 1 Cars]

I meant gasket sealant stuff for the inlet.

 

Ah gotcha my bad, I was thinking of using RTV. Anthony has many times and has had no problems

[SurGie 54]

I couldn't remember what its called, my mind went blank. RTV's the stuff i use in a clear colour

[welshpug 1,622]

pug do sell the gasket, as do most motorfactors.

 

only 3 places pressurised oil could be coming from on the front IIRC, two of which have a 16mm copper washer.

[Paul_13 212 1 Cars]

List of what needs doing:

 

Inlet off

Find oil leak

Remove plastic vacuum tube to inlet blank off and put servo hose straight on pump.

Fit loom off Miles Thanks again

Fit bottom engine mount

Fit OE top mount

Fit OE fork bushe

Sort out L bracket gear linkage bushes

Sort out clonking noise when braking

Sort out negative camber on drivers side wheel.

Driveshafts boots

Fit 205 diff

New inlet gasket

Build up 205 beam with new bars (22mm) and 24mm ARB. Using 6 arms again

Get SL434's refurbed

New tyres

Mintex 1144 pads for 266mm brake setup

 

 

Well I found the leak...

 

My suspicions from the oil here...

 

 

and here was confirmed

 

 

This was the culprit.

 

 

Never use a seal twice! When I found the cracked off section on the last block I didn't replace the flywheel seal... Lesson number 236 learnt.

 

Half way through

 

 

Loads of oil in the box causing the clutch to slip

 

 

Changed my vacuum setup to this \/ Saw this at Pugracing the other day and though it ws a good idea

 

 

 

Fitted the WMMS grp n lower bushe, bit of change see if it will make a difference in the cabin

 

 

Fitted the new rad hose courtsey of Cheesegrater, cheers mate

 

 

Outer CV's used to keep the bearings together in the hubs

 

Edited January 22, 2012 by Paul_13

[Paul_13 212 1 Cars]

How my boot looks

 

 

Pic for my reference

 

 

Pic of what should be a thread in the gearbox

 

 

Going to heli coil thread and sell on I think. Need this fixed soon so have bought a new box.

 

Oil oil everywhere, not a drop to spare

 

 

Motaquip wishbone after 3k, see if a new bushe sorts it if not i'll be contacting the seller. The bushe was rotating in the wishbone

 

 

More bits to get:

 

Flywheel bolts

Gearbox oil

Starter motor

Clutch cover bolts

Driveshafts

Wishbone bushe off Justin see if it fixes wishbone.

 

P.s Cheers for the friction plate Justin Mine was covered in oil.

Edited January 22, 2012 by Paul_13

[Miles 331 1 Cars]

I've yet to figure out why people connect the Earth up on the brown plugs

 

Crankseals can be a pain, Get a Payen one if you can as I have had one supplied by a customer which leaked more oil than I care to remember and when checked was a huge amount out compared to another one I had laying around

[SurGie 54]

Thats the reason i changed mine over when i fitted the lightened fly wheel, ill start the engine with the gearbox off just to make sure it's sealed well. Remember to use some moly grease on the lip of the new seal mate, then use the same sized drift, so it has a level seal.

[Daviewonder 533 3 Cars]

ill start the engine with the gearbox off just to make sure it's sealed well.

 

Doesn't the gearbox have to be on to hold the starter in place mate?

[SurGie 54]

Yeah it does, sorry tired again. I should have wrote, i'll fit the box then start it for a while, then take the box off and check it all over. After this it will be worth it because you have to make sure the seal is as dam near perfect fitted all round, knowing my luck it wont have

[cheesegrater 43 1 Cars]

Doesn't the gearbox have to be on to hold the starter in place mate?

Get a mate to hold it by hand

Looks like that leg touchs on the hose Paul, do they all do that?

[chipstick 382 1 Cars]

The vacuum pipe, what is the benefit from removing this.

 

The pic isn't that clear, where is the pipe going from the pipe? And what have you done at the servo end?

 

Whatever it is, if it's a benefit il give it a go

[chipstick 382 1 Cars]

The vacuum pipe, what is the benefit from removing this.

 

The pic isn't that clear, where is the pipe going from the pipe? And what have you done at the servo end?

 

Whatever it is, if it's a benefit il give it a go

[Paul_13 212 1 Cars]

Just a bit more simpler, less chance of leaks. I can't see the point of the pipe that goes to manifold.

[Miles 331 1 Cars]

That's why I never fit the pipe from the manifold, When you test the vacume on the pump it by far exceeds the manifold and if you fit bodies etc it's not used anyway, Better for left foot braking etc too

[Anthony 1,000]

Just be sure that the vacuum pump is in good order - a friend of mine runs this setup on his 306 (one of those so called "BTCC" inlet manifolds with no vacuum takeoff) and in stop-start traffic you run out of servo assistance because the vacuum pump is never spinning fast enough to replenish the vacuum lost each time the brakes are pressed.

 

With a good pump it'll be fine though, as clearly diesels don't have vacuum at the manifold and rely completely on the pump for providing servo assistance.

[Paul_13 212 1 Cars]

Bit of progress

 

Received the gearbox courtsey of Shuttle courier services (bought of Daza- Thanks!) and it's in pretty good nick. Input shaft is tight and everything came off nicely, it stands at the moment with no crownwheel and differential as I have separated these ready for the 205 diff swap.

Typically the threads have stripped: 5 out of 8 leaving me with 3 good ones. I was hoping to get the diff in this weekend, but this my delay things slightly unless we have a stroke of luck at Pugracing tomorrow.

 

Part number diff bolts: 311963/311959

 

 

I've removed all of the parts i'm reusing off the old gearbox and it's going to a good home at Pugracing.

 

 

Also started stripping the rear beam tubes I had lying about in the shed, 1 came out ok just full of grease and the other was ovalled quite badly. Removed the inner bearings using an old torsion bar (as a slide hammer) and collasped the upper bearings using a screw driver and hammer. Gave the good beam a clean with the jet wash and a thorough drying out after the picture was taken and everything is spot on.

Still have to remove the front bushes but need a drill for that. Ordered new ones of Constella and they come with a new nut and bolt each side.

 

 

 

Received new driveshaft seals off Baz aswell (cheers bud), these need to be renewed ideally.

Edited January 27, 2012 by Paul_13

[Paul_13 212 1 Cars]

Converted the gearbox to 205 earlier, swapped the gear selector arm earlier. Swapped the Xsara arm to the 205 item:

 

 

And the clutch arm and fork

 

 

Also changed the diff over, forgot to take pictures off this. The diff bolts from Pug are a different design to old.

 

Changed the flywheel seal but may of f***ed it up

[cheesegrater 43 1 Cars]

Go on....

[Paul_13 212 1 Cars]

Swapped the beam over on the GRD yesterday, worked out why it was making a grinding/rubbing noise:

 

 

Alot more stable now as the bearings on the old beam were grinding down and wicked handbrake action in the snow Highlighted the fact I definitely need some new front tyres!

 

Thanks to Anthony for pressing in the shafts and bearings at his and also to Tom Fenton for the ARB end plate bushes

 

Next to sort out the beam for the 205, the beam tube off the GRD is good so can be reused ready for some 22mm bars and a 24mm ARB I'll be in contact Miles for some more bits

Bling Bling!

 

 

Jobs for today are:

 

Fit new crank seal

Fit flywheel

Fit clutch

Set koni shocks to softest

Edited February 5, 2012 by Paul_13

[Paul_13 212 1 Cars]

Jobs for today are:

 

Fit new crank seal

Fit flywheel

Fit clutch

Set koni shocks to softest

 

 

Used the friction plate off of Kyepan, cheers mate

Also used new clutch cover bolts which are more to the job than the last.

The new fly wheel seal is sat slightly shallower than the last, much happier with it

 

Just waiting on diff bearings and the box can go on

Edited February 5, 2012 by Paul_13

[Paul_13 212 1 Cars]

 

Got these off Tom Fenton Cheers again.

 

Just waiting on the diff bearings to come through and the box can go back on

 

Also going to paint the new torsion bars soon, fitting the leathers into the GRD tomorrow night