MOT fail

[sgtflanders]

Hi all, MOT failed yesterday, both headlamps aim beam image incorrect, offside mirror insecure, excessive play in O/S/R tie bar, O/S/R brake cable restricted movement, O/S/R brake binding, front section exhaust (just in front of cat on the seam) leaking (hole!).

Last year went so well too!

Not looking forward to getting the front exhaust off, iirc access isn't good, combined with corroded exhaust fittings = headache!

[gumby6371]

Sorry to hear that but mostly easy fixes;
A new handbrake cable and a clean should sort the binding brakes and is easy enough.
New tie bar is simple enough but use plenty of your freeing agent of choice and wire brushing as it will probably be pretty rusty back there.
Not tinkered with my D9 exhaust but the D8 was a case of willing helper with a spanner holding the top nut while I had the ratchet and long extension from underneath, it is possible with 1 person but much easier with a third hand.
If it's in generally good nick you may be able to weld it in situ if you can get her on a lift.
Mirror will hopefully be a case of tightening things up, replacing glass if needed or just pinch one off a breaker. If you get a breaker part then just pop the colour coded bit off and put it on the replacement, the main body is the same for leccy and manual mirrors.
Headlights may need some investigation, do the motors respond to the cabin switch? if not maybe some contact cleaner on the connections will sort it if you're lucky. Obviously check the fuses but I'm pretty sure they have seperate fuses for N/S and O/S.

Good luck

Gareth

[Doggy]

We swapped the whole exhaust on my bro's old 1.9TD when he first got it. Discovered 1.9's were made with and without cats - so guess which one we fitted?

Getting it off wasn't a problem, but we struggled to get the front connection done up again. Eventually we settled for fitting the nuts, but no washers.

If the tie bar you're referring to is the top link, be aware this is fitted on an eccentric bolt, used to change the rear tracking, so would need to at least be checked afterwards....
viewtopic.php?f=27&t=21858&hilit=camber+adjustment

[gumby6371]

Reading Doggy's response has remind me the front is a bit fiddly to do up.
Put the exhaust on the rubbers to take the majority of the weight first. You should have 2 of each of these - bolts, springs, collets, nuts and washers.
The bolts are shouldered so you need to push them up as far as they'll go while holding the exhaust in position, both of which are pushing back at you due to the anti vibration springs.
If I were to do it again I might think about putting a longer bolt in 1 side to pull everything together, that gives you both hands to push on the other bolt aginst the spring tension while a willing helper gets a few turns on the nut from above.
Note the nut on the timing belt side is done by feel as it's hidden from view and if you suspect any leaks it's worth changing the seal at the mounting point while you're there. It's the compressed wire wool type thing the exhaust pushes against but will now be a dirty black colour rather than shiny silver.

[sgtflanders]

Thanks for all the replies guys, would have responded sooner but have been underneath getting muck and filth in my eyes!!

Just got back from retest and all sorted, tie rod was a bit of a pig, think it was the original one, new handbrake cable and drum clean up sorted the binding brakes.

glue has sorted the mirror.

headlights were really glazed, as polycarbonate units do. I got a headlight restorer kit from halfrauds (wouldn't normally but only place local that stocked it) bit pricey at £21 but did the job lovely and plenty left for future jobs, not to mention saving a fortune on new units.

exhaust was £55 inc vat (with cat) from local parts store, local exhaust centre wanted £20 to fit it so I took their arm off bearing in mind the access to the front bolts is quite nasty and I haven't got a 3 way arm.

another 12 months sorted, Im determined to get this motor to 200k.

Thanks again all

[GingerMagic]

That's a good result. If you can get a car through an mot for £150 then that works out at less than 50p per day for the year......

Also means its less to fix next year......

[Doggy]

Well done, that man!

As GM says, it could've been worse.

Was the tie rod the one upper link with the eccentric bolt? If so remember to check the rear tracking or at the very least keep a careful eye on your rear tyres - I've been caught out twice with a seemingly half worn tyre that turns out to have the canvas showing on the inner edge.

[sgtflanders]

Yes, upper rod with eccentric bolt. I marked it when it came off so hopefully not far off. Will have to keep an eye on it.

[dirtydirtydiesel]

Just be aware that the tie rods can vary in length , this will mean that your tracking will be out even though you marked it.
This can lead to some very old handling from the rear end, take it from someone that know's

[sgtflanders]

Im hoping it will be ok. It was the same length as the one removed and so far handling is spot on. Only time will tell I guess.