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Make for benefit and glory of Poptop T3

Discussion in 'Resto Corner' started by SunnyJim, Apr 22, 2019.

  1. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    Barry
    I don't think I could detect that. I am not that sensitive. Well that's what my wife says :D
     
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  2. Barry

    Barry Well-Known Member

    Messages:
    3,494
    Location:
    Abbotsford NSW
    I am leaving that well alone :D:D:eek::eek::rolleyes::rolleyes:
     
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  3. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    Today Borat gets his pushrods oil switch changed. It is tucked a little way back there and a standard socket wouldn't reach, but this el cheapo bunnings tap sockets worked a treat, size 24mm to be precise.
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    Last edited: Jul 7, 2019
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  4. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    This was just supposed to be a basic clean up. I have done more than i thought would have but pulling things apart is a great teacher .
    Moustache bar mounted, exhaust back on, oil cooler o ring done. New rubber hoses on the coil cooler. Oil breather tower o ring replaced.
    Just waiting on the flywheel o ring and front seal to arrive then starts the process of re install.
    20190708_153328.jpg
     
  5. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    If i was going to do this, then I gotta do it right.
    Borat was shaking so much a while back mostly due to that broken alternator bracket but the exhaust was loose in many places .
    It is real solid now having secured the exhaust bracket back to the motor.
    20190708_154354.jpg
     
  6. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    You all getting sick of me and Borat yet? He gets prettier by the day... Borat Hemsworth has a nice ring to it.:p

    Anyway the alternator is not critical as before i pulled the motor i checked it was charging at 14.1v so that is ok. However the brushes are well worn and a bit of corrody gunk around.

    It is not noisy, looks solid, so the plan was to just replace the regulator and brushes.
    I assume it is a bosch but I cant see a label.
    Anyone know what the 2 small black plastic boxes on the back are? Haynes does not show these.

    20190709_124840.jpg 20190709_124226.jpg 20190709_124923.jpg
     
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  7. rstucke

    rstucke Well-Known Member

    Messages:
    914
    Location:
    Wamberal NSW AUS
    They're capacitors to reduce static on your radio.
    2.2uf
     
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  8. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    Ok makes sense
     
  9. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    20190710_142034.jpg 20190710_140401.jpg
    Hydraulic clutch is a first for me.

    While Borat's engine is out i have been cleaning up the engine bay. I removed the throwout bearing then noticed the clutch slave cylinder pushrod fell out. Then i looked up Haynes and realized there should be rubber bellow or boot around that pushrod. Not sure when it went walkabout.

    Here is what I am not sure about. I just ordered the boot today. It will be a few days , but I will want to reinstall the motor asap. If i reinstall all the clutch gear and motor now, can i still easily put the rubber bellows over the clutch slave cylinder pushrod? Or will it be under a lot of tension and to hard to get the pushrod out?
     
    Last edited: Jul 10, 2019
  10. Syncro27

    Syncro27 Well-Known Member

    Messages:
    6,082
    Location:
    Terrigal, NSW Central Coast
    That slave cylinder is in a shit of a spot.

    A little easier with the gearbox out.

    I gave that job to my mechanic. :D
     
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  11. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    Scott
    It is easy access to the slave cylinder right now as i have the engine out. Little bit tougher with engine in .

    Right now there is no real tension in the bellhousing, the throw out bearing had no pressure on it without the clutch .

    So this is what I don't know, trying to find out . I am ready to reinstall clutch, pressure plate flywheel and motor but then that puts tension on the clutch. In order then to put the new boot on I need to remove that clutch slave cylinder pushrod and put the rubber bellows over it and new circlips. So I don't know if this is possible with clutch , motor in.

    The hitch is I am still waiting for the rubber bellows to arrive .

    Like to hear from someone who has done this job.
     
    Last edited: Jul 11, 2019
  12. cbus

    cbus Well-Known Member

    Messages:
    11,658
    Location:
    sunshine coast
    You can remove clutch slave with engine and box in situ.
    It's just harder to get at. :mad:
     
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  13. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    Col
    Thx mate. I can see i can remove that slave cylinder but I didn't want to disturb the liquid side of it as it is all neat and clean.
    I will need to prise the clutch pivot arm down remove the pushrod , push the bellows over the pushrod, then reinsert the pushrod back in. I was concerned that clutch plate pressure will not allow me to do this.

    I will get in and give it a go.
     
  14. cbus

    cbus Well-Known Member

    Messages:
    11,658
    Location:
    sunshine coast
    That could be difficult.
    May be necessary to undo the bolts holding the slave.
    It will sit higher without needing to undo fluid line.
    One of the bolts is a mongrel to get at tho.
     
  15. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    Turned out a little easier , bought a complete slave cylinder boots and clips, replaced the whole lot.
    Col u are right, 1 bolt was a bugger.
    Also replaced the transmission input shaft seal.
    New alternator voltage regulator installed.
    Front and rear main seals done.

    Motor slowly inching forward to its final destination. 20190712_154308.jpg 20190712_103901.jpg
     
    Last edited: Jul 12, 2019
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  16. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    Struck a little problem, advice welcome from t3 gurus

    Sat arvo, got the engine in, and could not turn the crank. It is stuck , Ok , I thought I have not aligned the input shaft therefore it is binding. Nope not it.

    So pulled it all out again and realised something funny with the flywheel.
    When I removed the flywheel I can now turn the crank. But when I torque the flywheel bolts to 60nm as Haynes it locks up. I even tried 50nm but still locks up.

    Any advice? I have had this t3 for a few months , it was not in the road for a few years but this motor was running before albeit a bit smoky and shaky.
    New front and rear main seals new flywheel o ring 20190713_165508.jpg 20190713_165518.jpg
     
  17. Grantus

    Grantus Well-Known Member

    Messages:
    15,572
    Location:
    Southern ACT
    Are the shims and disks between the crankshaft bearing and oil seal, installed in the correct order? :rolleyes:

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  18. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    Grantus
    I think you are onto something, I reckon I got that big square one in the wrong order.
    Now I only just put a new rear main seal in yesterday.
    I will have to remove it without any damage. Any tricks to this?
    I was just thinking using a wide blunt screwdriver slowly going around pulling it out?
    Haynes says 60nm then 90degrees , so i guess that could be your 110nm? 20190713_173530.jpg
     
  19. Grantus

    Grantus Well-Known Member

    Messages:
    15,572
    Location:
    Southern ACT
    The previous two pages of the Bentley:

    F19B1C3E-BA03-4760-B8FF-6D93DA94E638.jpeg
     
  20. SunnyJim

    SunnyJim Well-Known Member

    Messages:
    1,557
    Location:
    carindale Brisbane
    Grantus
    Thx for those 2 pages, Haynes book does not have that detail
     

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