Project HaeThere! (Coupé restoration)

[mjb]

Oh and on that note - did you find out the problem with the gearbox? Is it a BE3 or the later one?

Aye - brake fluid reservoir over-full and dripping into the gearbox. Flushed it out and it's a lot better now although I think I need to re-fill it again after buying a new drain plug+seal as I think it's been leaking


NEW PROBLEM!

Economy's down about 5% on what it should be, the throttle response is piss poor (not good when i'm having to double-declutch everywhere to make it last a bit longer), I'm lacking torque across the band and power's non-existent under 4000rpm. Any ideas? Reckon it was more than one cylinder I wasn't firing on or could there be something else?

[mjb]

Oh yeah and I do have a little bit of a positive update on this:

The auto-dimming mirror is definitely shafted. Paying close attention it gets mildly dark just to the side of the centre when you cover the sensor. So I got a new one from ebay for £15. Not quite right, it's the one from the 807, but it is brand new (was delivered still sealed in the PSA box ). Figured out how to split it from the mount, but I'm still trying to work out how to get the hefty metal clip back around the balljoint when I switch the units. I can't even get it back on without the ball in position

[mjb]

Just a little update since I've done virtually nothing on it the past few weeks:

1) I've replaced the mirror with one from an 807. It works, but it's switched off because it darkens way too easily

2) I've made the rear brake backplates a hell of a lot smaller by removing the bloated rust bits and hammering it about a bit. Think the only noise left now is from the rear tyres

3) Discovered the power steering funny business isn't so rare on the V6, but the only sign I've found of it being fixed is someone who discovered the aux belt was slipping due to a duff crankshaft pulley. Oh yay...

4) Been getting lots of ELECTRONIC IGNITION FAULT and BRAKING FAULT messages. Suspect a duff battery or insufficient charging due to the aux belt slipping perhaps?

5) Decided to get some Firestone TZ200s on the rear. Not too expensive, and supposed to be nice and quiet.

6) Got a strange whistling sound while accelerating at high revs (always had it, forgot to put it here). Reckon it could be due to a slipping belt or dodgy pulley

7) The clutch is in dire need of replacement. Guessing I've got about 2 months before it stops being able to move itself. Thankfully I should be moving to the new house (with the garage!) in a month's time. Going to be straight in there with a clutch change I think!

[mjb]

50mph, 5th gear, 2000rpm and the clutch slips if I give it more than about 20% throttle

PLEASE PLEASE PLEASE just let it give me another month. 4 weeks to the day and I'll be in my new house, I'll have a garage, clutch kit, lower engine mount, thrust bearing. I'll also have my dad's turboless tubby as a runabout as I'll be fixing it after doing my clutch. Just 4 weeks. PLEASE! 4 weeks.

[Welly]

Nurse that clutch baby, Nurse it

Tis a brave man who changeth the clutch of a V6 in one's garage with nothing more than an axle stand and a Halford's Gift Voucher

Have you got a definitive how-to?

[mjb]

Nurse that clutch baby, Nurse it

You won't believe just how smooth my driving is at the moment, especially the downshifts where I'm double-declutching everything and managing to get over 95% of shifts perfectly rev-matched

Tis a brave man who changeth the clutch of a V6 in one's garage with nothing more than an axle stand and a Halford's Gift Voucher

What gift voucher? If I run out of tools or botching ability, it's going to be sat there for a month until I get paid

Have you got a definitive how-to?

Nope, what I *think* I'm going to try to do is:

remove the clutch slave cylinder, hopefully without detaching the pipework
remove the air filter box, gear linkage, reverse switch connector (slackening the switch), crack the gearbox mount
shove it on axle stands
remove the undertray
empty the oil
remove the wheels
undo the lower balljoints on the wheel hub carriers and use a crowbar(???)(need to buy) to lever off?
pull the the wheel hubs off the driveshafts
pull the driveshafts out of the gearbox
remove the speed sensor
change the lower engine mount
change the CV boots
support the gearbox
remove the gearbox mount
remove the gearbox->engine bolts (i have no idea about these)
drop the gearbox out
unbolt the clutch plates, discard
remove the thrust bearing parts, discard
then the opposite of all the above

All that of course is 100% guesswork. I have very little idea what I'm supposed to be doing I can see myself ending up with a pile of oily cogs falling on my head... I mean, there's so much I have no clue about, like how to dismantle the lower steering balljoints and put them back, or how to undo/redo the clutch plate from the flywheel when the flywheel's going to want to turn?!? or how to change the cv boots, or what grease to use where, and ARGH!

I'm sh*tting bricks over this job, but every penny counts for the next 2 months

[Welly]

Bejesus what a job, I bet many a grown man hath shed a tear over that bastard.

I'm just sorry I can offer no advice, no advice at all

Actually I could say have you thought about ringing Mr Crutch or somewhere for a price? they're a bit rough and ready but they are there to fit you a new clutch afterall - however painfull or however many times you need to go back there after

[mjb]

Actually I could say have you thought about ringing Mr Crutch or somewhere for a price?

I've already found someone that could do the job for peanuts, but it's peanuts I can't afford and would require a drive up to lancashire, which I suspect the car may not make

Besides, you don't learn when someone else does the job

[steve_earwig]

What I learned from changing fwd clutches was get someone else to do it 'cos they're a pain

[Doggy]

Not one for the faint-hearted, I've heard it's a 10.5 hour job on mine, can't see the v6 being easier.

Maybe jasper or someone else in the know can confirm, but I think you've got it about right.
I haven't done a clutch for many years, but I do recall the necessity to align, (centralise), the friction plate just about spot on, or you'll never get the gearbox input shaft to engage. You can hire a gadget to do this, (my dad used to shave a bit off the end of a broom handle)

Good luck Matt

[jasper5]

It's a big job, for sure.

If it means doing it yourself, then I would aim to remove the gearbox one day and refit it the next, take your time and be careful, the gearbox is very heavy to handle all by yourself.

As dogslife says, lining up the new clutch is critical for getting the box back in without too much trauma.

You will need a good sized trolley jack to support the gearbox on removal and refitting.

Get yourself something comfy to lay down on, if there is a local furniture foam supplier, go round and ask for what they call "skins" that is a piece of the block of foam that gets cut off from the block before they cut the foam to sizes, it has a plastic backing and a foam backing to lie on ( I get these from my sister, she has a foam supply company).They are scrap, so should give them away.

You seem to have a fair idea what is required, but I would look to see if the battery box can be removed, you will have much more room with it removed.

I will post a how-to when I have a bit more time.

[mjb]

If it means doing it yourself, then I would aim to remove the gearbox one day and refit it the next

I'm expecting it to take at least a week and a half, probably a fortnight. That's 3 trips to the stealers for some part that's broke/non-replaceable. Yes, I'm a pessimist.

You will need a good sized trolley jack to support the gearbox on removal and refitting.

Got one thankfully. Got to be careful how high I jack the front end up though, make sure I can still reach the gearbox

Get yourself something comfy to lay down on, if there is a local furniture foam supplier, go round and ask for what they call "skins" that is a piece of the block of foam that gets cut off from the block before they cut the foam to sizes, it has a plastic backing and a foam backing to lie on ( I get these from my sister, she has a foam supply company).They are scrap, so should give them away.

TOP TIP!!! Would this place be where I should be looking? http://www.foamfurnishings.co.uk/ - it's the only thing for "foam products" on yell.com

You seem to have a fair idea what is required,

That's news to me!

but I would look to see if the battery box can be removed, you will have much more room with it removed.

good idea. how do you silence D9 coupe alarms (no keyhole in boot)? sod it, i'll pull the siren

I will post a how-to when I have a bit more time.

and hopefully I'll be adding pictures to it in 4 weeks time!

[jasper5]

The foam furnishings place sounds ok, depends if they get the raw blocks that have to be "skinned", but they should have some scrap foam lying about, it really is great for lying on to do jobs like this, where you will be lying on the floor for hours.

[Welly]

The foam furnishings place sounds ok, depends if they get the raw blocks that have to be "skinned", but they should have some scrap foam lying about, it really is great for lying on to do jobs like this, where you will be lying on the floor for hours.

.......just try not to fall asleep on the job

[STALLED]

WOOOOOO HOOOOOOO!

Maybe getting a place with a carport/garage - BRING ON THE DIY!