2.5N/A to 200tdi conversion

landowner · Dec 8, 2011

jamesmartin said:
300 tdi rods all look the same just a little longer

Just measure the shortfall and weld a bit of rod in

GRATCH · Dec 8, 2011

jamesmartin said:
maybe not quite so far out but 20mm ,is fork on pivot correctly ,clutch plate

Clutch plate in (see 2nd piccie, post #24 for clutch plate being aligned by my technical clutch aligning tool). I'm certain (but now starting to doubt) that the fork and release bearing are fitted properly.

GRATCH · Dec 8, 2011

landowner said:
Just measure the shortfall and weld a bit of rod in

But it seems that it's at the fully in position so I don't think this will work.

jamesmartin · Dec 8, 2011

the only way it can be to short ,is wrong rod ,release arm bent ,poor release bearing ,clutch fingers in too far because plate wrong way round poor clutch

GRATCH · Dec 8, 2011

Gonna take it out and double check everything james, as I'm certain everything was fine. Oh, AP lockheed clutch kit so should not be poor.

jamesmartin · Dec 8, 2011

no it shouldnt but i have had them but still my prefered clutch, theres not too much to be wrong

landowner · Dec 8, 2011

It looks like he 300 rod that I've got has a spacer on the end which fits snuggly ito the clutch release arm.

Looks like it could be an attempt to solve the problem of the rod pushing through the arm.

I used to use high tensile bolts on the minis, cut to length and rounded off at the ends, This solved the problems with mix and match engine / clutch bits and bobs.

Could be you have the wrong rod or cylinder

GRATCH · Dec 9, 2011

Okay, dropped the box out today and found.......

....clutch assembled correctly- friction plate right way, release bearing in correctly, release arm straight, rod is right 'cos it's not been off the release arm.

But......

I tried a different release arm and it seemed to be better positioned but I wont know till I put the box back on the engine and I think the pivot ball may be worn as well.

jamesmartin · Dec 9, 2011

id change pivot then worn rough it will eat its way through arm

GRATCH · Dec 9, 2011

jamesmartin said:
id change pivot then worn rough it will eat its way through arm

Yep gonna do. You know the part number?

jamesmartin · Dec 9, 2011

frc5180

GRATCH · Dec 9, 2011

GRATCH · Dec 13, 2011

Not done much lately except be evicted out of one shed into another

This was how the clutch push rod was sitting in bellhousing pushed in and pulled out

and this is what the pivot ball looked like

Put a new HD clutch release arm in while I was at it. So gotta put the box back on and start again at where I'd got up to.

jamesmartin · Dec 13, 2011

thats as bad as one ive ever seen

Sean · Dec 13, 2011

looks like it's been in salt water for a year then blasted with very heavy grit - think it's past it's best

GRATCH · Mar 13, 2012

Forgotten about this, plus I not actually bin able to do anything on it for a while. So update....

Gearbox back in, handbrake attached and adjusted, front and rear props bolted back on, clutch slave cylinder attached and bled (clutch disengage seems to be at bottom of pedal travel, may have to bleed again), disco engine loom soldered onto 90 loom plug.

Doozil pipes fitted (now got jubilee clips on)...

Rad mounts shortened...

Trial fitting of rad and intercooler pipework...

And I'm thinking of mounting the air filter on the un-used aircon compressor mount.

GRATCH · Mar 24, 2012

She lives

Bodged up the oil cooler pipes and turned the key and into life she fired

Need to find some proper size pipe for the oil cooler and repair the bleed screw on the doozil filter as it's stripped

Oh.........and put the rest of it back together

Langers · Aug 25, 2012

GRATCH said:
She lives

Bodged up the oil cooler pipes and turned the key and into life she fired
Need to find some proper size pipe for the oil cooler and repair the bleed screw on the doozil filter as it's stripped

Oh.........and put the rest of it back together

Question for ya... can you remember the size of the pipe you used to extend the oil cooler pipes?

Thanks

GRATCH · Aug 25, 2012

Langers said:
Question for ya... can you remember the size of the pipe you used to extend the oil cooler pipes?

Thanks

Nope. It was some pipe that was 'lying' around at work that was a good fit.
I'll have a look this week if I remember.
I really must get round to finishing it, 14 month old twins don't help with my free time

Langers · Aug 26, 2012

GRATCH said:
Nope. It was some pipe that was 'lying' around at work that was a good fit.
I'll have a look this week if I remember.
I really must get round to finishing it, 14 month old twins don't help with my free time

My guess is around 14mm id. I'll find out for sure when I cut the pipe.

Cheers anyway -- thought you would have finished it months ago!

2.5N/A to 200tdi conversion

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