New Project

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jasper5
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Re: New Project

Post by jasper5 »

I'm not sure if anyone needs a guide for replacing the reluctor ring or CV joint/CV joint boot or just removing driver's side driveshaft for sorting out the lower mount, but here goes anyway :D

This is what the reluctor ring looks like when it has failed...I've removed the brake disc and caliper as I'm fitting new discs, it's actually a lot easier to replace the CV joint/reluctor ring with the disc off.

Image

To start off....if you have steel wheels undo the wheel bolts and pull out the clip at the end of the driveshaft and remove the castle fitting then undo the 35mm nut, it WILL be tight!
If you have alloy wheels take off the wheel and pull out the locking pin and remove the castle fitting, refit the wheel and undo the 35mm nut.

If you are not replacing the discs undo the 21mm nut on the bottom ball joint then screw the nut back on a few threads to protect the threads when you hit the bottom suspension arm.....if you are changing the discs at this time, remove the caliper and the caliper bracket 13mm and 17mm spanners to undo the bottom caliper swivel then swing the caliper away from the disc before removing the caliper... cable tie it or something to keep it out of the way.
Remove the caliper bracket 2xT55 bolts....these can be tight but mine were not :D

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Take a good size hammer and hit the side of the bottom suspension arm to free off the ball joint.

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Using a pry bar...I used my breaker bar....pull down on the bottom suspension arm and free the ball joint from the bottom arm.
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Pull away the wheel hub to expose the driveshaft...

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If you are removing the driveshaft completely, now is the time to undo the 2 inner bolts on the shaft....2x11mm nuts then pull out the shaft from the gearbox....you should have already drained the oil by now :D
If you are changing the lower mount you can now undo the mount bolts and the bracket from the engine.

If you are changing the reluctor ring knock off the old ring ....mine just fell off...and clean up the surface where the ring fits...make sure there is no rust left, it must be spotless before you fit a new ring.
Make sure the reluctor ring is the correct size....there are 86mm inner diameter and 90mm inside diameter as far as I know.....the teeth are the same number.....48.
To fit the ring you must heat up the ring until it is a blue colour...use a plumbers torch, welding torch or put the ring on a gas ring to heat it up....fit it onto the CV joint and allow it to cool down naturally.

If you are fitting a new CV joint, hit the back of the joint until it springs off the driveshaft....remove the CV joint rubber and the metal ring from the driveshaft and clean up the shaft.

If you are just fitting a new CV boot be careful hitting the CV joint...use a wooden drift and normal hammer or a copper/plastic headed hammer.

The 2 types of CV joint on my car...

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Make sure you have the correct CV joint, there are different types....

If you have now fitted your reluctor ring then refit everything in reverse order.

If you are fitting a new CV joint or new boot slide the new rubber boot onto the driveshaft then take the new joint and the CV joint grease, pack the new joint with grease and slide the joint onto the shaft without fitting the clip...work the grease into the joint by turning and twisting the joint on the shaft.

The joint packed with grease....sorry about my focus fail :oops:

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Once you worked the grease in properly remove the CV joint and fit the new clip to the shaft.

The new clip...

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Before you fit the new clip get your mole grips and squash the open bits of the clip into a more "round" clip this will help when fitting the CV joint as the clip will not stick out and stop the joint going on smoothly.
Carefully ease the clip onto the shaft.
Screw on the big nut a few threads to protect the threads, offer up the joint onto the splines of the shaft and tap the shaft until it is fully home....if it won't go on easily take off the clip and squash it some more.

Fit the new rubber boot onto the CV joint and fit new clips.

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Refit the driveshaft into the hub, fit the nut and tighten a bit....refit the bottom ball joint and tighten the 21mm nut.

Rebuild everything.

Here is the finished job just before final tightening of the big nut.

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I hope you found this useful 8)
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steve_earwig
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Re: New Project

Post by steve_earwig »

Very nicely done sir! :cheesy:

Another one of yours for the KB I do believe :wink:
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Captain Jack
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Re: New Project

Post by Captain Jack »

Very, very useful for me, John! Should have a couple of free hours tomorrow morning, so will try and tackle this then!

And nice job, as always :cheesy:
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Doggy
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Re: New Project

Post by Doggy »

Very useful guide, just the right amount of detail. 8)
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jasper5
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Re: New Project

Post by jasper5 »

Latest update....

Fitted new aux belt tensioner and idler pulley, the old ones were completely knackered.

Nice quiet aux belt now :D

£43 for the 2 items....Gates ones fitted.
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Captain Jack
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Re: New Project

Post by Captain Jack »

You'll pretty much have a brand new car. Isn't it still under 70k?
2003 - 2008: 1998 Peugeot 406 2.1 TD 110bhp LX Saloon
2008 - 2009: 2004 Honda Accord 2.2 CDTI 136bhp Executive Saloon
2009 - 2013: 2002 Peugeot 406 2.0 HDI 110bhp Executive Saloon
2013 - 2021: 2007 Peugeot 407 2.2 HDI 170bhp Executive Saloon (mapped to 213bhp :twisted:)
2021 - ????: 2016 Ford Mondeo 2.0 TDCi 180bhp Titanium
Sonia406
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Re: New Project

Post by Sonia406 »

Doing well Jasper, love reading the updates :D
Best keep it and attend all meets :D
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jasper5
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Re: New Project

Post by jasper5 »

Captain Jack wrote:You'll pretty much have a brand new car. Isn't it still under 70k?
89,234 as of today.

Still got a few jobs to do before I'm happy with it.

Going to Bradford on thursday to have the COM2000 unit repaired.

BTW...anyone know where the fuel filter is located?
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Doggy
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Re: New Project

Post by Doggy »

Image

No. 15?

Looking forward to seeing you all and your new car, at Cosford. 8)
2002 HDi 2.2 Exec Estate, (2008-12) (wonderful)
2003 HDi 2.2 6-speed Exec Estate (2012-19) (also a gem)
2009 Citroen C5 2.0 HDi VTR+ Estate (godawful heap)
2008 BMW E91 330i touring (great fun - murdered by a reversing SUV)
2007 BMW E91 325i touring (slower smoother quieter)
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steve_earwig
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Re: New Project

Post by steve_earwig »

Took me a while to spot that - it's near enough in the middle :roll: There's always the chance it doesn't have one...
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Bailes1992
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Re: New Project

Post by Bailes1992 »

Bare in mind the HPi basically uses the same kind of fuel system as a HDi. I would hope to god with fine tipped injectors and HP pumps that it has a filter!
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steve_earwig
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Re: New Project

Post by steve_earwig »

Now that is a good point - I hope so too :cheesy:
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Doggy
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Re: New Project

Post by Doggy »

Fairly sure I've got the right drawing - (when you select the one for the injector pipes it shows a camshaft driven HP pump). Seems you need to select the 2.0i engine variant with no bhp figure, (naturellement).
2002 HDi 2.2 Exec Estate, (2008-12) (wonderful)
2003 HDi 2.2 6-speed Exec Estate (2012-19) (also a gem)
2009 Citroen C5 2.0 HDi VTR+ Estate (godawful heap)
2008 BMW E91 330i touring (great fun - murdered by a reversing SUV)
2007 BMW E91 325i touring (slower smoother quieter)
jasper5
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Re: New Project

Post by jasper5 »

Doggy wrote:Fairly sure I've got the right drawing - (when you select the one for the injector pipes it shows a camshaft driven HP pump). Seems you need to select the 2.0i engine variant with no bhp figure, (naturellement).

Thanks, Eric, I'll buy a filter and fit it tomorrow :D
jasper5
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Re: New Project

Post by jasper5 »

Today's update :D

I went over to Bradford this morning to have my COM 2000 repaired.
I let the guy who does the job do everything whilst I waited.The COM2000 indicator problem I had has now been well and truly fixed, the indicators have real feel and are tight with a good response when self cancelling.

I'm very happy with the job and the service received....£30 for the job plus £8 for repairing my keys and new batteries. :D

Anyone else needing their COM2000 units repaired, this is the guy I went to.....http://www.ebay.co.uk/itm/COMM-2000-PEU ... 2a31fa8154

Big thanks to Doggy for the info :D
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