Friend just text back saying he can bring tools down... bit late now I guess, sorry!!
 
So fixed the disco this morning, quite simple really :)

First job, get a brew on the job...

null_zps784e5f2c.jpg


Pulled out rocker shaft, snapped underneath no4 pedestal, clean break around the bolt.

This gave access to the no5 pedestal hole which was indeed stripped

Ran a tap down it and to my joy I found the hole was deeper, much deeper in fact than the stud was long!

So, I thought a fix was on the horizon!

Got a bolt, m8x1.25 x100mm - must be 8.8 grade or better!

null_zps804b3836.jpg


Ran the bolt into the hole and luckily it was oily so it showed the depth nicely...

null_zps5b30f363.jpg


This demostrated the difference!

Cut the bolt into a stud at the correct length to screw all the way into the head.

And that was it, job done :)

Throw it back together and we're good

73BEC1D8-51FA-4449-A25F-A400894C2DD7-1570-000001D9210EC797_zps1bbcc7f7.mp4


Now, if you're a high mileage or long distance/overland user, I'd recommend doing this mod to all 3 studs at least and maybe the 2 bolts aswell!

Cheers, Sam
 
No because you need the longer part on top, it holds the pedestal first with 1 nut then the rocker cover on top with second nut!
 
So fixed the disco this morning, quite simple really :)

First job, get a brew on the job...

null_zps784e5f2c.jpg


Pulled out rocker shaft, snapped underneath no4 pedestal, clean break around the bolt.

This gave access to the no5 pedestal hole which was indeed stripped

Ran a tap down it and to my joy I found the hole was deeper, much deeper in fact than the stud was long!

So, I thought a fix was on the horizon!

Got a bolt, m8x1.25 x100mm - must be 8.8 grade or better!

null_zps804b3836.jpg


Ran the bolt into the hole and luckily it was oily so it showed the depth nicely...

null_zps5b30f363.jpg


This demostrated the difference!

Cut the bolt into a stud at the correct length to screw all the way into the head.

And that was it, job done :)

Throw it back together and we're good

73BEC1D8-51FA-4449-A25F-A400894C2DD7-1570-000001D9210EC797_zps1bbcc7f7.mp4


Now, if you're a high mileage or long distance/overland user, I'd recommend doing this mod to all 3 studs at least and maybe the 2 bolts aswell!

Cheers, Sam

:)
a good fix mate - impressed.
its one to remember for this old boy, just incase....
 
Looked at it and it was a tidy break halfway through the pedestal so plenty of purchase still

Was in the mood for throwing it back together and using the car rather than waiting for parts that I don't need so that's what I did :p
 
Wouldn't do it on my v8 mind but the tdi is more of a workhorse for us and receives minimal expenditure (so I can waste it all on the off-roader!)
 
I've sourced a new rocker shaft for £20 and im picking it up tomorrow so 'fixits' are coming out. Interestingly after removing my rocker shaft today its in 4 pieces! And its also missing 2 valve caps! But at 25p each im replacing all 8 anyway just a bit worried on where they've gone. Ive searched everywhere for them, push rods out nope not there. .........
 
Maybe they were never there?

Or they've trickled into the sump where tbh they'll be safe

Mine have always luckily sat in the head (cambelt went once and we ran it for months without knowing it had ultra bent pushrods and 10mm of valve clearance!)

Good luck!
 
Maybe they were never there?

Or they've trickled into the sump where tbh they'll be safe

Mine have always luckily sat in the head (cambelt went once and we ran it for months without knowing it had ultra bent pushrods and 10mm of valve clearance!)

Good luck!

Im guessing they've been off for a while now because I had to adjust the tappets a couple of months ago so I should of checked then! I've done an oil change since then so fingers crossed they came out then!
10mm jesus. Surely it was tapping like hell??
 
It was bizarre

Did timing belt

Idler failed within 15 minutes, teeth slipped etc etc

Fitted another timing belt kit, timed up, all good

Ran the car for months and decided to do valve clearances whilst it was in

Checked them and found pushrods like cheesestrings :eek:

God knows how it was even running but I guess that's why it failed the emissions that year on the mot (had to bodge it through on a diesel/petrol blend after cleaning inlet and de-egr etc didn't help)

At the time I didn't know pushrod damage needed checking on these engines that's why I didn't look

Just assumed it was ok seeing as it was running! :p

Anyway so after some trials and tribulations it's been a good old motor :D
 

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