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1st June 2015, 23:16
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#361
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West Midlands
Join Date: Nov 2005
Location: Nuneaton (West Mids)
Posts: 13,835
Car(s): '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
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Frustrating day today, had full intentions to get the gearbox off, swap the clutch, reassemble and maybe have some of the front suspension back on again at last.
But.... As ever nothing is that simple. My displeasure in the XU setup has only been enhanced, I really do miss the ease of TU that I've been accustomed to in the past. Eventually after plenty of arsing around negotiating the gearbox removal past the nest of wiring, hoses etc the gearbox eventually came off.
Now those who have read through my progress will remember how much of an oily state the underside of the gearbox was, and that with so much gunk and dried oil buildup I had no chance of identifying where the cause of the problem was. Well the top of the gearbox and inside the housing was the same.
Really did need seeing to prior to refitting
Nuts anyone?
And the clutch fork (thank god I did decide to do the clutch now) was actually semi broken. The rear of the clutch fork that fits onto a pivot point ball had begun to detach with one of the welds having broke.
So until a replacement can be sourced I've started to clean up the gearbox. About 3 hours later and here's where I've got to
Still room for improvement. So very much feeling like 1 step forward but 3 steps backwards after today. *sigh*
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2nd June 2015, 22:04
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#362
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Saxperience Post Whore
Join Date: Aug 2008
Location: The wrong carpark
Posts: 5,152
Car(s): Xantia 1.9TD
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I know the feeling man, it'll be worth it in the end. Mine needs a clutch ideally and im dreading it as they're a pig to do. You're almost there
At least it hasn't decided to leak fuel everywhere!
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8th June 2015, 23:01
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#363
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Saxperience Post Whore
Join Date: Oct 2005
Location: Sydney
Posts: 8,525
Car(s): Mango Westcoast
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Much tidier now Willsy
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12th June 2015, 09:05
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#364
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West Midlands
Join Date: Nov 2005
Location: Nuneaton (West Mids)
Posts: 13,835
Car(s): '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
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The Following 2 Users Say Thank You to willsy For This Useful Post:
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12th June 2015, 16:01
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#365
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Newbie
Join Date: Jun 2013
Posts: 26
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cracking update
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14th June 2015, 19:13
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#366
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Saxperience Hardcore!
Join Date: Aug 2004
Location: West Mids
Posts: 15,392
Car(s): '98 EK9 N1
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Matt, cars coming along so well. Need to sort another get together so we can catch up. I can introduce your OCD to my cars too.
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17th June 2015, 07:35
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#367
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West Midlands
Join Date: Nov 2005
Location: Nuneaton (West Mids)
Posts: 13,835
Car(s): '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
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Cheers Rushy, and yes we do it's long overdue again. I wish more people would let me loose on their cars, it's a shame there's no market in it to go into such detail on other peoples cars & do this as a job- I'd love it though
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19th June 2015, 10:04
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#368
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West Midlands
Join Date: Nov 2005
Location: Nuneaton (West Mids)
Posts: 13,835
Car(s): '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
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Finally I have all the remaining parts to crack on with refitting the gearbox.
I've had plenty of time to clean the gearbox up, degreaser and metal polish were used in abundance.
I've fitted a host of new (Genuine Peugeot) parts by way of; new seals to the input shaft, the old ones were fine but for the sake of a few quid it's worth doing whilst the gearbox is off. Failed clutch fork replaced, the additional clutch lever found on the BE1 box has been replaced, that was virtually seized with the rusty bolt and bushes passing through it. New clutch cable fitted, reverse sensor replaced too.
I'd had a new starter motor sitting as one of the first things I bought for the car. The old one still works but again with the gearbox off it was an ideal opportunity to fit the new one. The old one is quite a lot heavier and more bulky.
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19th June 2015, 11:52
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#369
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Established Member
Join Date: Aug 2009
Location: King's lynn
Posts: 2,073
Car(s): Turbocharged vtr
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Gearbox looks great compared to what it looked like before
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1st July 2015, 20:24
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#370
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West Midlands
Join Date: Nov 2005
Location: Nuneaton (West Mids)
Posts: 13,835
Car(s): '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
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Slow progress at the mo, mainly due to the heat being unbearable.
I have started buying all the bits to do the brake system with. I've invested in a flaring kit.
Here's my tester. Combination of A4 Marine Stainlesd fittings and cupronickel lines
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8th July 2015, 21:45
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#371
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West Midlands
Join Date: Nov 2005
Location: Nuneaton (West Mids)
Posts: 13,835
Car(s): '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
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Just a couple of photos from the last few days.
New master cylinder fitted along with the brake lines which I made up. Cleaned out the brake fluid reservoir and cap which were pretty grubby too
This is the best 'before' pic that I have
And a selection of 'So far's' Servo can wait til I strip out and respray the engine way
And gearbox refitted. From this;
To this
New clutch lever bits
Other than that I've just been trawling through all the wiring checks.
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9th July 2015, 08:25
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#372
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Saxperience Post Whore
Join Date: Aug 2010
Location: Little Mill, South Wales
Posts: 7,547
Car(s): Mondeo ST TDCI
Saxo VTS
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Fairplay I love reading your restoration threads.
Epic work, wish I had (a) the money and (b) the time to do things like this.
__________________
Quote:
Originally Posted by Giraffe
I'm happy being a north easternly smoggie bender.
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14th July 2015, 19:55
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#373
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West Midlands
Join Date: Nov 2005
Location: Nuneaton (West Mids)
Posts: 13,835
Car(s): '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
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Quote:
Originally Posted by Brettles1986
Fairplay I love reading your restoration threads.
Epic work, wish I had (a) the money and (b) the time to do things like this.
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Cheers mate, it is a huge labour of love. Even the simplest things take a lot of time and patience to resolve.... As my next update demonstrates
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14th July 2015, 19:56
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#374
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West Midlands
Join Date: Nov 2005
Location: Nuneaton (West Mids)
Posts: 13,835
Car(s): '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
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I've made a return to the electrical checks today, starting with the front wipers and washer neither of which were working.
I'd already replaced the wiper arm spindles which are well renowned for seizing up on these. Next up was replacing the relay, still nothing.
Then took the wiper stalk apart, cleaned up the connections a few of which were definitely in need of it, still nothing.
Next up I wired the motor up directly and it worked fine, as did the washer motor which was new.
So that just left the wiring and connections
Out came the rotary tool with a small brass wire brush, electrical contact cleaner and metal polish.
Turns out they clean up quite well. Cleaned up the outside aswel as the inner surface for no reason other than it was quite satisfying
As good as new
And the hard work paid off. Front wipers and washer are now fully functional :-)
Next up was the rear wiper. On the Phase 1 309's the power travels through the boot gas struts (Good old peugeot) with a spade terminal on either end. I'd already fixed the lower ones as the wires had snapped at the terminal, I've got exact OE terminals so they were an easy fix. The rears work off a button on the dash rather than the stalk. Washer motor worked fine but no life from the wiper.
Took the motor and spindle apart, fitted a new motor. The old one did work after all so it'll retire to being a spare. Remembered to refit the upper terminals on the gas struts and still had nothing.
Eventually realised that the boot has to be fully closed for it to work. Job done
Apologies for the essay anyway. Just goes to show how long it can take to complete some of these jobs. It's taken me 6 hours of diagnosis and tinkering to get the wipers and washers fully functional so I'm now relieved and feeling quite pleased.
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16th July 2015, 21:02
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#375
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Saxperience Post Whore
Join Date: Aug 2008
Location: The wrong carpark
Posts: 5,152
Car(s): Xantia 1.9TD
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Suprised you didn't just suspend the plug in a pot of contact cleaner. Although i'm not sure how much fuzz it would have removed!
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27th July 2015, 20:00
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#376
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West Midlands
Join Date: Nov 2005
Location: Nuneaton (West Mids)
Posts: 13,835
Car(s): '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
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Finally turned a corner, all MOTable electrics (lights, washers etc) are now fully functional. I just have a few final switches to check and then I can get the dash and remaining interior refitted.
It's been so time consuming and it's not really anything that I can take some pics of without boring everyone to death.
Rest assured though, progress is good just need to finish the brake refurb and then hopefully the big day will soon arrive
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28th July 2015, 18:14
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#377
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Saxperience Forum Bum
Join Date: Dec 2012
Location: Perth
Posts: 3,663
Car(s): Peugeot 106 1.1 Turbo
Peugeot 106 1.5D Turbo
Peuge
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All MOTable electrics?
That means a bulb will blow at the MOT
__________________
The rain kept a trollin'
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29th July 2015, 12:43
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#378
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West Midlands
Join Date: Nov 2005
Location: Nuneaton (West Mids)
Posts: 13,835
Car(s): '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
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Quote:
Originally Posted by MartinObviously
All MOTable electrics?
That means a bulb will blow at the MOT
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That would be just typical :-)
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29th July 2015, 12:43
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#379
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West Midlands
Join Date: Nov 2005
Location: Nuneaton (West Mids)
Posts: 13,835
Car(s): '64 Volvo V40 R’Design, '89 Ph1 309 GTi, ‘97 Mk1 S
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Been trying to get some key front end bits cleaned up and treated that have contact with new suspension bits before fitting them. The rest will be done when I respray the engine bay etc at a later date.
The upper suspension turret had some surface rust where the contacts been with the old top mount
Got as far as cleaning all the rust off with drill & wire attachment. Any remains have been treated with Bilt Hamber rust removal gel to ensure it's a perfectly clean surface. Then two coats of Bilt Hamber electrox high zinc primer as my base
Onto the front subframe mounting points. Again minor surface rust to contend with
Cleaned it all up and again treated with the Bilt Hamber stuff to ensure it's perfectly clean. Zinc primer applied straight after this pic
And a final pic after some paint and lacquer has been applied
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30th July 2015, 19:01
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#380
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Saxperience Post Whore
Join Date: Aug 2008
Location: The wrong carpark
Posts: 5,152
Car(s): Xantia 1.9TD
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hope you'll be doing the same to that brake pipe bracket
I don't think anyones car will match this level of detail!
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