MrAndy 10 Posted July 16, 2019 It's been long time without updating anything. Bought a set of B6 dampers and will install them with Eibach springs. Meanwhile I've been cleaning and painting the front suspension parts. Hope to get that finished and the front end put together soon. -A- Share this post Link to post Share on other sites
SootySport 23 Posted July 16, 2019 How do you keep track of all the work on 4 cars? I have trouble with just one. Keep up the good work. 1 Share this post Link to post Share on other sites
MrAndy 10 Posted July 22, 2019 (edited) After long time, took the gearbox end cover out to replace it with a repainted one and found a surprice. The input shaft end nut (with holds the 5th gear packet together) has become loose causing some ugly-looking marks. The fifth gear things looked like OK and there was no bigger particles in the oil, but the oil was very dark as you can see. Now asking for opinions how to continue? 1. Best choise, remove and open the gearbox, wash everything clean inside and then rebuild. + The front suspension and driveshafts etc has already been removed. + This would ensure everything to be 100% OK - I've just finished everything on the engine bay side and everything is working there, it feels that if I now put everything into pieces again, I will never get this car running (I had big hopes to be able to do some testing this summer and maybe even try the MOT and now this happened) 2. Put the cover back on and put the suspension back together. Fill/rinse/flush the gearbox couple of times with diesel&oil mix and rotate it in the air engine running idle. Then putting new oil in and be happy + Much easier solution than 1. - Will it be clean enough after this?? - Will the cleaning liquid come trough the seals and spoil the clutch plate and clutch fork pressure-bearing?? What would you do?? -A- Edited July 22, 2019 by MrAndy Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 Here is a small instruction set of how to build rear brake calibers, if anyone is interested: 1. All parts cleaned and ready to rebuild.. -A- Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 2. First thing to do is to install the hand brake seal. Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 3. Hand brake Screw and spring washers Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 4. Nice drawing to show how the spring washers will be installed Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 5. Hand brake lever parts before installation - I used lot of Black MOS2-Grease on all the parts not contacting directly to rubber gaskets /seals and CRC-Brake grease on parts that are in contact to rubber seals and/or brake fluid itself. Correct me if you have different opinions on that. 1 Share this post Link to post Share on other sites
Gohn 62 Posted February 15, 2021 good pictures and info andy, you must have a 205 magnet in your pocket, they just stick to you ! noticed the ones imported to finland have the little headlight squirters, haven't seen them before did you end up rebuilding your gearbox ? or flush and run new oil in it ? 1 Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 6. Hand brake lever installation #1 - I used Wise to squeeze the spring washer packet enough to get the lever into place. Be carefull with that and PROTECT YOUR EYES!!! Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 2 minutes ago, Gohn said: good pictures and info andy, you must have a 205 magnet in your pocket, they just stick to you ! noticed the ones imported to finland have the little headlight squirters, haven't seen them before did you end up rebuilding your gearbox ? or flush and run new oil in it ? Hi Gohn, thanks!!! The headlinght squirters are a Nordic option. (FIN / SWE / NOR) at least in Finland they were mandantory at that time. The red car with gear-box-thing is waiting my decision to go full route or not (to paint the whole car properly or not). I got tired of not running any of those for too long time and decided to get the Grey GTI into MOT and driving condition for next summer. So the brakes are the GREY-GTI-brakes. -A- Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 7. Hand brake lever #2 - Here you can see the Auxiliary spring alignment. Don't forget to put it in - GREASE ALL places Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 8. After sliding the lever into place, put the Locking ring into the groove also Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 9. The aux spring before and after snapped into place - I used a sharp screw-driver for installation Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 10. Protect the whole assembly with MOS2-Grease - This part is messy, thought this for a long time, but I have put 2 of these into pieces and both were done like this originally (from 2 different cars..) so decided then to do the same thing. Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 11. The main rubber cap on. - Challenge, try to do this without messing your hands =) Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 12. Brake piston parts before installation Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 13. The spring and pressure/thrust bearing waiting to be put into piston. - The spring end must go into the small hole inside the piston bottom - I lubricated this with fresh brake fluid Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 14. Piston installed and ready to be put into cylinder - Slide the seal first into the groove (WITH GREASE) - The piston goes nicely in (WITH GREASE) by pressing and rotating same time clockwise Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 15. Piston installed and dust seal waiting for installation - I used the CRC-Brakelube with these parts Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 16. The dust seal installed - You can see nicely the fabrication date stamped here Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 17. The sliders waiting for installation - The is nothing special putting them in QUESTION??? - The pin ends are different (thick vs narrow), which direction is correct for installation? Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 18. Complete - QUESTION - In these pictures you can see the direction I selected to install the sliding pins. Is this correct way?? Share this post Link to post Share on other sites
MrAndy 10 Posted February 15, 2021 19. The atmosphere of the work site Share this post Link to post Share on other sites
cybernck 400 1 Cars Posted May 13, 2021 What a superb guide! 1 Share this post Link to post Share on other sites
