tag:blogger.com,1999:blog-45975174401115188222024-03-28T06:37:32.984+00:00Restoration of a 1968 Citroen DS21bvh PallasOne mans journey into the heart of darkness: a blow-by-blow account of my efforts to put my beloved Citroen DS back on the road after a 16 year lay up.Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.comBlogger135125tag:blogger.com,1999:blog-4597517440111518822.post-91689621825633222942023-07-09T19:21:00.001+00:002024-02-25T17:08:29.723+00:00Dropping the Engine Back in to the Chassis<div style="text-align: justify;"><span style="font-family: arial; font-size: small;">Now this really was a BIG milestone. </span><span style="font-family: arial; font-size: small;">The engine is back in the chassis!</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcvpRtw2X6WljkziJzSdTvpqVlOxsmEVODx1fMFvvlwIKQeYU7MwS9HLYgWJQXqDJ3Z26znSDxZluQr0XS97Zskaei-QeHGrpwPYq0bu25Mej5cjLoG4NY8GXVXQXmGov79TGBEeCbm3dNS67k714bGYJZTRLMgYcuEqN2UkHtRWQqvurLSmseDZfH/s4032/IMG_7067%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcvpRtw2X6WljkziJzSdTvpqVlOxsmEVODx1fMFvvlwIKQeYU7MwS9HLYgWJQXqDJ3Z26znSDxZluQr0XS97Zskaei-QeHGrpwPYq0bu25Mej5cjLoG4NY8GXVXQXmGov79TGBEeCbm3dNS67k714bGYJZTRLMgYcuEqN2UkHtRWQqvurLSmseDZfH/w640-h480/IMG_7067%20copy.jpg" width="640" /></a></div>I've been building up to this since the day the engine was taken OUT of the chassis! </span><span style="font-family: arial; font-size: small;">Way
back then, my friend Richard - a fellow DS owner/ driver - had talked
me into pulling the engine out and had been around to help on the day
in question.</span><span style="font-size: small;"><span style="font-family: arial;"> Probably to make sure I didn't back out. </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpIA_dV5uIzElstzQ27jW5TpJyLXPxv-ZEwza47duqjKZaNm4xArKMS8uWVJkwuU4XMHXy7VUiEHQtEQJRKiA9R1UgOs2ffa4dCYXVqeH7OrpEwrwLxqoCxRS5J8FJya3wHQv2mveo9GNco0z34nT6GVOGq4PJdCTQ859engsk0vea2bLnxa3Cz8Qk/s4608/DSCF0585.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3456" data-original-width="4608" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpIA_dV5uIzElstzQ27jW5TpJyLXPxv-ZEwza47duqjKZaNm4xArKMS8uWVJkwuU4XMHXy7VUiEHQtEQJRKiA9R1UgOs2ffa4dCYXVqeH7OrpEwrwLxqoCxRS5J8FJya3wHQv2mveo9GNco0z34nT6GVOGq4PJdCTQ859engsk0vea2bLnxa3Cz8Qk/w400-h300/DSCF0585.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">June 2015.......</span><br /></td></tr></tbody></table><br /></span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjM2K0Fg11zmAYdYtJRbNMw4G4tXH_C8jwpJ_H8Kl42gObcNI603mvC3ZiCpYVHT74Qbgj_aolcKKHxifQ-B3zoHalwAaU29mtL6mNhcRe4JYeLLr7L4km-2DqVLNVPtKhsXLnBMVcl19THzXla7zPECi5cRB0gndHGghwCXmU1SZKbm3G85bHFw3j/s4608/DSCF0581%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3456" data-original-width="4608" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjM2K0Fg11zmAYdYtJRbNMw4G4tXH_C8jwpJ_H8Kl42gObcNI603mvC3ZiCpYVHT74Qbgj_aolcKKHxifQ-B3zoHalwAaU29mtL6mNhcRe4JYeLLr7L4km-2DqVLNVPtKhsXLnBMVcl19THzXla7zPECi5cRB0gndHGghwCXmU1SZKbm3G85bHFw3j/w400-h300/DSCF0581%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">.....and a very recently removed engine.</span><br /></td></tr></tbody></table><span style="font-size: small;"><span style="font-family: arial;">Putting the engine back in is ideally a two person job, so a few weeks ago I contacted Richard and asked for his help. To be honest, I think he'd had have been offended if I hadn't asked him. He'd been there when I first tried to get the car running again. He'd been to see my car several times over the years and was watching my progress. I think this was almost as a big a moment for him as it was for me. With a date set, it had been a last minute rush to get everything ready in time, so that the job was as straightforward as possible on the day. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span><br /></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">On the big day, I tied all the stray hoses and hydraulic pipes in the engine bay out of the way and similarly bundled up all the hoses and belts haning off the engine. I mentally 'walked' through the refit job for the umpteenth time.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikZDiNrmTNKoJElbijqgFlSlc65lX2beHc1R1-ZnDU2xm2L-3-dxqstvWm8CZc_c9bYasecG7G-OGtJ1VJErumhKFEcy3F8okL2dML4sA2cJl5mXrYlm7NrJsFzy7wTwTz4V3Jdl2Qk44IM7mu-dX5B5vj1RdPkPagGJEqsTGI_lfEPfGIi99bXaTo/s4032/IMG_7062.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikZDiNrmTNKoJElbijqgFlSlc65lX2beHc1R1-ZnDU2xm2L-3-dxqstvWm8CZc_c9bYasecG7G-OGtJ1VJErumhKFEcy3F8okL2dML4sA2cJl5mXrYlm7NrJsFzy7wTwTz4V3Jdl2Qk44IM7mu-dX5B5vj1RdPkPagGJEqsTGI_lfEPfGIi99bXaTo/w400-h300/IMG_7062.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Patiently waiting for an engine</span><br /></td></tr></tbody></table>Richard arrived and after tea and some pleasentaries we addressed the 'elephant in the room' and got stuck in. With Richards help I used my trolley jack to move the car back out of the garage again, to give us some working room. With that done the car was lowered onto a pair of sturdy axle stands and the back wheels were chocked.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I
have seen engines put in from the side and from an angle at the front. I
planned to put my engine in from the front. Being a 1968 car, the front
cross member - the one that the horns fix to, and that the craking
handle is stored on - can be unbolted. Which gives improved access for
the reach of the crane. Leaving the car on axle stands instead of front wheels also
meant that it was more stable and a little easier to manouevre the engine
stand without the wheels getting in the way. </span></span><br /><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWGtEr_DXcXzeonmUBz6YsNbC3M_dw0bjClpFLdEyc7FHIlrq2ZrSbs1UPuK_bFnst1R6bTz92aD-ekmGqjI0h16I5y7vCJS9QcmEmICf5xQcrAqvPN7zVWw1T-VXtWLx5bqz1ddSkCkAeSxzx3lbrPlGJ_3DxZX8A3qHYhxJvHhEUKGImYNIbzX5U/s4032/IMG_7061.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWGtEr_DXcXzeonmUBz6YsNbC3M_dw0bjClpFLdEyc7FHIlrq2ZrSbs1UPuK_bFnst1R6bTz92aD-ekmGqjI0h16I5y7vCJS9QcmEmICf5xQcrAqvPN7zVWw1T-VXtWLx5bqz1ddSkCkAeSxzx3lbrPlGJ_3DxZX8A3qHYhxJvHhEUKGImYNIbzX5U/w400-h300/IMG_7061.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Getting nearer.....</span><br /></td></tr></tbody></table></span></span></div></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I'd
even remembered to adjust the links of the chain holding the hook on
the jib so that the hook naturally sat in the right alignment to the
engine hook on the car's water pump body, and did not try to twist the
engine as we dropped it in. The engine was wheeled in front of the car and the crane attached. </span></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwQR_qYKCA5U650COGZMmDNfTSO5sb1LrWmCtoh0HvDtUnkPBS5eI0LT0Vic8OauspZ01-FsMQTjc1s7Jqkvz0sDQtWc4p8TszpsWLoB33Y8ZoOWET5JSoeNx7iXto8KXIK8vNewAzIye48RCN7MhE-7eTyhHBeZkukUHOcVSS0G6amuumxw9Ey5RS/s4032/IMG_7060.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwQR_qYKCA5U650COGZMmDNfTSO5sb1LrWmCtoh0HvDtUnkPBS5eI0LT0Vic8OauspZ01-FsMQTjc1s7Jqkvz0sDQtWc4p8TszpsWLoB33Y8ZoOWET5JSoeNx7iXto8KXIK8vNewAzIye48RCN7MhE-7eTyhHBeZkukUHOcVSS0G6amuumxw9Ey5RS/w400-h300/IMG_7060.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Nearly ready....</span><br /></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">That's
when I remembered I needed to check the height of the rear engine
mounts! This has to be done with the engine weight on them (so before I
lifted the engine with a crane). I'd already made a template for
checking the heights and dug it out.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQkqeAj2JB03sDtcgbk_owyWHy5jd65A3YPb18GOIxRo51lxczeUIze-su7wTFC_lfxjo2m4tEs7NRH4WEkxgPPPr24Z68spHLIRN4WJPdxTYAMHBEHU0t_xbbiV5LqJtLwDy7Gu3G9578VS_hDAoAP7DR74dTt8CavTFaZP0oDUXaGiUzEgYFRNtP/s4032/Engine%20mount%20template.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQkqeAj2JB03sDtcgbk_owyWHy5jd65A3YPb18GOIxRo51lxczeUIze-su7wTFC_lfxjo2m4tEs7NRH4WEkxgPPPr24Z68spHLIRN4WJPdxTYAMHBEHU0t_xbbiV5LqJtLwDy7Gu3G9578VS_hDAoAP7DR74dTt8CavTFaZP0oDUXaGiUzEgYFRNtP/w400-h300/Engine%20mount%20template.jpg" width="400" /></a></div> As my template helpfully reminds me, the procedure for setting the engine mount height is at Operation DX.133-0. That can be found in manual 518. However you can also find the instructions in volume 1 of manual 814. I used cardboard simply because it was easier to cut.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhS5c4PUgJFJWMR15FTM4ySIzXXkSU0VnHcK6H0lyp2HqKAEaNEJGOd_4GS82c13MzxbO788ckUfaPLM3Ck5HvKRiQVhetRaetQLPAd6IkW-aqFmPp6-UOe_v94cf7yyZmm7Ut_YhqjZoXjYn-hNTJRh03fug0NycuEOw9LfPTv6Ji9vgMyA7uAh4Zx/s836/engine%20mount%20tool%20dimensions.jpeg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="836" data-original-width="543" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhS5c4PUgJFJWMR15FTM4ySIzXXkSU0VnHcK6H0lyp2HqKAEaNEJGOd_4GS82c13MzxbO788ckUfaPLM3Ck5HvKRiQVhetRaetQLPAd6IkW-aqFmPp6-UOe_v94cf7yyZmm7Ut_YhqjZoXjYn-hNTJRh03fug0NycuEOw9LfPTv6Ji9vgMyA7uAh4Zx/w260-h400/engine%20mount%20tool%20dimensions.jpeg" width="260" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: small;"><span style="font-family: arial;"></span></span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container"><tbody><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Dimensions for the tool to set the engine mount height<br /></span></td></tr></tbody></table></td></tr></tbody></table></span><span style="font-size: small;"><span style="font-family: arial;">The instructions and tool dimensions are the same for manual and bvh cars. The measurement is meant to be made with the engine complete and in running order. My car didn't have a radiator fitted but being a bvh car had a centrifugal regulator and other parts that a manual car would not have. </span></span><span style="font-size: small;"><span style="font-family: arial;">I decided it was just about as heavy as it was going to get and made the measurements.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Because of the design of my wooden engine stand, the engine had not been resting on it's front engine mount - it had been propped under the gearbox. Using the crane and a lifting strap, the gearbox was lifted by its cross beam. The tool was applied and the top nut and lock nut adjusted to give the desired heights. Like this.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYZhaSnW7-4CaEGhGYLkH1LIYJ4kk1OuuEjLxd_lIaq0LtFVxD17n8lajeNyM7qWfSAGBZ9gOJRVSiMeMrJ5GIQeYdrF6gJ7hwrZNaTXl4Rb1WVqLlmfN9MYh72dy_RCY22wCzS4OPi3hwf5ahIqY1JQ-_e9ik1pHmZNJViX0lEoDtq4poH4mEoMva/s805/engine%20mount%20tool%20in%20use.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="805" data-original-width="537" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYZhaSnW7-4CaEGhGYLkH1LIYJ4kk1OuuEjLxd_lIaq0LtFVxD17n8lajeNyM7qWfSAGBZ9gOJRVSiMeMrJ5GIQeYdrF6gJ7hwrZNaTXl4Rb1WVqLlmfN9MYh72dy_RCY22wCzS4OPi3hwf5ahIqY1JQ-_e9ik1pHmZNJViX0lEoDtq4poH4mEoMva/w266-h400/engine%20mount%20tool%20in%20use.jpeg" width="266" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Using the tool to check and set the engine mount height</span><br /></td></tr></tbody></table> Given
my recent worries over the hydraulic seals in my engine crane, the engine was gingerly lifted a
few inches from it's trolley and we put the kettle again and waited to see
what happened.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAUoDThGTf1WztRbAeSPiuSm3cROt9gQt4iGdrwSA5GulD3MqNHh_-xgotB2hyphenhyphenErOgHFD3FHxtOngtNDQTJKDQgmklvTfwkSRjDNzzB-qvBxwgysLCP-FPKJ-sexihk6wx8c8lB2ieYz8m4PUa1PruTN5jpmzP3qUhLH85YKe3I-VH7IlIb9qVvf9T/s4032/IMG_7063.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAUoDThGTf1WztRbAeSPiuSm3cROt9gQt4iGdrwSA5GulD3MqNHh_-xgotB2hyphenhyphenErOgHFD3FHxtOngtNDQTJKDQgmklvTfwkSRjDNzzB-qvBxwgysLCP-FPKJ-sexihk6wx8c8lB2ieYz8m4PUa1PruTN5jpmzP3qUhLH85YKe3I-VH7IlIb9qVvf9T/w400-h300/IMG_7063.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">'Make or break' time - quite literally....</span><br /></td></tr></tbody></table>There was no obvious sagging while we were away and so the engine was lifted higher and it's wooden trolley removed.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH21Sfxbf8B3BBYBUW6IT7lHJItQfpwjwq8VdIOwoCO12Ll8czhZiD6yQX4eKx1Mnv7e2ndQxZwS_UY3WmBYoytsVMgH67aPduCW-JuKe1XsSDZ8Mmd5fWqIvNhlJ9-CptiyOBxBpPbNwXgPKIM_fpvSZewcJlRs_Jkqc79XFg5aYGVa30NvWCkr0o/s4032/IMG_7064.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH21Sfxbf8B3BBYBUW6IT7lHJItQfpwjwq8VdIOwoCO12Ll8czhZiD6yQX4eKx1Mnv7e2ndQxZwS_UY3WmBYoytsVMgH67aPduCW-JuKe1XsSDZ8Mmd5fWqIvNhlJ9-CptiyOBxBpPbNwXgPKIM_fpvSZewcJlRs_Jkqc79XFg5aYGVa30NvWCkr0o/w400-h300/IMG_7064.JPG" width="400" /></a></div>Slowly and nervously the engine was introduced to the car: "hello engine.....". "Hello car.....". I took a few photos but manouvering the engine and raising it/ lowering at the same time took both our efforts.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhua2nMCj0PpHwS71VseUbw3lyc5R5D8ge_wp3eCNNVaPFtIhMmgCjN6LwtdW2UFki6PpVBW7VYBE0p5pibjTRMCNnw2_ofJwlJMrKu1IlogGx84dBNb2uqN0zHDMmO-mfG0jR3Pdw5mId6K_r6alP17cIk5iY-ySBUNbUAOv5CPlIZtR0zm3uGMiIa/s4032/IMG_7065.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhua2nMCj0PpHwS71VseUbw3lyc5R5D8ge_wp3eCNNVaPFtIhMmgCjN6LwtdW2UFki6PpVBW7VYBE0p5pibjTRMCNnw2_ofJwlJMrKu1IlogGx84dBNb2uqN0zHDMmO-mfG0jR3Pdw5mId6K_r6alP17cIk5iY-ySBUNbUAOv5CPlIZtR0zm3uGMiIa/w400-h300/IMG_7065.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">I just KNEW Richard would be pleased to help.....</span><br /></td></tr></tbody></table>With the crossmember in the engine bay removed, and the engine crane jib at half-stretch (it's 'half ton' postion) there was *just* enough room to manouvere the crane so that the engine was where it needed to go.</span></span></div><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtFM1yewJdvI-msjn4XgafxNJE-EQGvrdnYX5qWxjJFqySU9rOEzYW37W-7xborWuHLXv-8LC3HQgOsK_wMt__jDhU_7QaKQvKYJVmmWXJeqv9gi45bPCXswg4NnYKF5oHBx_Yj4kvOKpS_jR35Z1C7J2JDRNbil4-IsNJ0hqovXThCFGOVhINyz6x/s4032/IMG_7066%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtFM1yewJdvI-msjn4XgafxNJE-EQGvrdnYX5qWxjJFqySU9rOEzYW37W-7xborWuHLXv-8LC3HQgOsK_wMt__jDhU_7QaKQvKYJVmmWXJeqv9gi45bPCXswg4NnYKF5oHBx_Yj4kvOKpS_jR35Z1C7J2JDRNbil4-IsNJ0hqovXThCFGOVhINyz6x/w400-h300/IMG_7066%20copy.jpg" width="400" /></a></div>I man-handled the engine in to place while Richard lowered the crane arm inch by inch. </span></span><span style="font-size: small;"><span style="font-family: arial;">Worried
that my engine crane would suddenly fail, I was keen to get this over
and done with as soon as possible, but several times we had to raise the
engine and respoistion it before moving it into place again. I was surprised at just how little spare room there was around the engine: there was a matter of millimeters to spare between the engine and the gear brain. </span></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmcXdIq5EfX-LSeVvToUCRoFyE1uby5EPcshm1JCHzZG1n7EudA9gi5EwdyRUecj9iSG2ArFBoDqwXw-KsaWN8niiKDpjnjg57CCb5CxEG5IcbglK21pER36-bBCxuhIcm3lkBR4t7yvUVwOE7F9KWQ7Ho1a7-L351gyxkI0Xs8lXsp25sUAQoRX5W/s4032/IMG_7107.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmcXdIq5EfX-LSeVvToUCRoFyE1uby5EPcshm1JCHzZG1n7EudA9gi5EwdyRUecj9iSG2ArFBoDqwXw-KsaWN8niiKDpjnjg57CCb5CxEG5IcbglK21pER36-bBCxuhIcm3lkBR4t7yvUVwOE7F9KWQ7Ho1a7-L351gyxkI0Xs8lXsp25sUAQoRX5W/w300-h400/IMG_7107.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">How does it all manage to fit!</span><br /></td></tr></tbody></table> I
was also surprised at the angle at which the engine slid in - the
timing chain end had to be held down at an angle for the engine to slip
under the scuttle. </span></span><span style="font-size: small;"><span style="font-family: arial;">But at the same time it had to be high enough for the
exhaust down pipe to clear the bar across the bottom of the engine bay.
</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">With some nervousness the pressure in the engine crane was reduced just enough to lower engine an inch at a time and - suddenly - it was in.</span></span><span style="font-size: small;"><span style="font-family: arial;"> We
lifted the weight of the engine again and made a micro-adjustment to
line up the number four spark plug hole and bolt holes for the engine mounts. With
great relief we moved the crane out of the way and bolted the engine
down.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrg3ofWqYxr8XiQBUxaY4wsnaVLh45QVI454l1M3pv8Z1cxX64qOHaZPClkFQcXpGCSJ1bstkS1jTEp_2T6ljpRCbCmiAkoVgiS1OLroFR2uOc6tns27qPAnI6yksgvqH0lUYMVXdzVCKbUGlqeVekHu5QDHx9gLFvkCScnHcjfqYYNdiggii3Mx8m/s4032/IMG_7074.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrg3ofWqYxr8XiQBUxaY4wsnaVLh45QVI454l1M3pv8Z1cxX64qOHaZPClkFQcXpGCSJ1bstkS1jTEp_2T6ljpRCbCmiAkoVgiS1OLroFR2uOc6tns27qPAnI6yksgvqH0lUYMVXdzVCKbUGlqeVekHu5QDHx9gLFvkCScnHcjfqYYNdiggii3Mx8m/s320/IMG_7074.JPG" width="320" /></a></div></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The rear engine mounts needed several wobble extensions on the ratchet to navigate the necessary angles to bolt them in place. We tried to fit the drive shafts to the gearbox output housings but found that we couldn't reach the expected torque setting on about half of the twelve bolts. It was clear that threads were being stripped somewhere. Removing one of the bolts we found a delicate curl of sharp steel.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrsnqDR5gdOy4-ea7lMoO_ExN4iB2U-M27fyaMGfdFFrepgoAl7umo_xhv-s8GaKxoqStVBzd3ukKln7I2WM76qAQvB0khx-qgmEcohQhtf6voBnzTjOkc7_KdXKCISUt5mMjUKYxoNoJVdkmakuvAYhROtMjJcAH3zBzFYl9I6jLon7idHo6eo_of/s4032/IMG_8026.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrsnqDR5gdOy4-ea7lMoO_ExN4iB2U-M27fyaMGfdFFrepgoAl7umo_xhv-s8GaKxoqStVBzd3ukKln7I2WM76qAQvB0khx-qgmEcohQhtf6voBnzTjOkc7_KdXKCISUt5mMjUKYxoNoJVdkmakuvAYhROtMjJcAH3zBzFYl9I6jLon7idHo6eo_of/w400-h300/IMG_8026.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The thread from a stripped nut! (and a bag of replacements)</span><br /></td></tr></tbody></table>This was the thread stripped from the nut! We did up as many as we could for the moment but I will probably order some new nuts. With some old tyres fitted the car was wheeled back into the garage.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTyEk6XmtFOvoTUYnHXEGqS_u8YOSx1RztMi239X65KZlrth8vUjPzJcJDEC1-N1akDXU_G8qyPBiEwC3PqQsR_3wuRBGBzbYlo7Pi-ZwY0SRCHVxrV5HGuW_9Ay-CruxKgDVM7jR6CXZIZPDm6V4zHUs6ez9WkwLdAhzLIMIhyJOZsIEBv0hfy8ZH/s4032/IMG_7102.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTyEk6XmtFOvoTUYnHXEGqS_u8YOSx1RztMi239X65KZlrth8vUjPzJcJDEC1-N1akDXU_G8qyPBiEwC3PqQsR_3wuRBGBzbYlo7Pi-ZwY0SRCHVxrV5HGuW_9Ay-CruxKgDVM7jR6CXZIZPDm6V4zHUs6ez9WkwLdAhzLIMIhyJOZsIEBv0hfy8ZH/w400-h300/IMG_7102.JPG" width="400" /></a></div><span style="font-family: arial;">The kettle went on for a celebratory tea and we spent our time admiring Richard's car </span></span><span style="font-size: small;"><span style="font-family: arial;">and making under-bonnet comparisons.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlzwWdV5f-iv1e3eNBiLi4IcsalQzzIdPyLRlvCou4Y3-EfV_h72uYFHivvDUI6JntLazgpHyfUaW-GK0lxR2yKhhN88QtaocL0cOF4L7dsJHe8rFI6PDFycuJQg_q3uxPmJ0nEmLX7ZMPo3j5xArH1VCtvkweLSM9prGioG79xW4b_AdZw2lErYGS/s4032/IMG_7077.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlzwWdV5f-iv1e3eNBiLi4IcsalQzzIdPyLRlvCou4Y3-EfV_h72uYFHivvDUI6JntLazgpHyfUaW-GK0lxR2yKhhN88QtaocL0cOF4L7dsJHe8rFI6PDFycuJQg_q3uxPmJ0nEmLX7ZMPo3j5xArH1VCtvkweLSM9prGioG79xW4b_AdZw2lErYGS/w400-h300/IMG_7077.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Richard's (1972?) DSpecial</span><br /></td></tr></tbody></table> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghgZ9uGrRSJYfhicvZfGr_T2IbmoI_x9deH1Hit8tRL6P4KPsPp5Ges-J6WB2J03r61q9MF_PN1R2tvsIfM7wRPrwhV5ds6Wslxo3utMUMJ9WbeqFeU2-1vmCbRC64XTXrQb7-VQRSk9YoJxnmP4WG8n7kgKADMOnJ0_dorQA3EbCCaX6UPpqrD4aR/s4032/IMG_7078.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghgZ9uGrRSJYfhicvZfGr_T2IbmoI_x9deH1Hit8tRL6P4KPsPp5Ges-J6WB2J03r61q9MF_PN1R2tvsIfM7wRPrwhV5ds6Wslxo3utMUMJ9WbeqFeU2-1vmCbRC64XTXrQb7-VQRSk9YoJxnmP4WG8n7kgKADMOnJ0_dorQA3EbCCaX6UPpqrD4aR/w400-h300/IMG_7078.JPG" width="400" /></a></div> If I'm honest, and after many years of wondering about what this day would be like, my thoughts were never far from the milestone we had just achieved with my car and the next phase of jobs it now enabled, and I imagined my car being parked up on the drive way in the not too distant future.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Thank you Richard.</span></span><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuvALYFmX0eqDYqYINpCQLLsv-LZMOT1uO62-4j3RQAjT7ZseZlo7nLtpVBOCkfFX0h6pkrHqyeoKBNmzOEyWpFlVMGNmeCj_5O98OIGKGA4Uh-aF8PoEjH3JnCyb-dJKuiCxi2zxz7GsM1hu-5CTe3FQJ-9fPB9TEWQs02ntS2gKZ9UB01F0er2H8/s4032/IMG_7075.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuvALYFmX0eqDYqYINpCQLLsv-LZMOT1uO62-4j3RQAjT7ZseZlo7nLtpVBOCkfFX0h6pkrHqyeoKBNmzOEyWpFlVMGNmeCj_5O98OIGKGA4Uh-aF8PoEjH3JnCyb-dJKuiCxi2zxz7GsM1hu-5CTe3FQJ-9fPB9TEWQs02ntS2gKZ9UB01F0er2H8/w400-h300/IMG_7075.JPG" width="400" /></a></div></span></div></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-33853245302833444992023-07-08T18:11:00.601+00:002024-02-25T17:06:39.728+00:00Disc Brake Calipers And Final Preparations<div style="text-align: left;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"> This isn't very visual at all, as I was too busy to take any photos.<br /></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><b>Re-acquainting the engine and chassis <br /></b></span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The engine needed to be moved from my workshop into the garage. Not as straightforward as it sounds. A DS is long and with the car in the garage, there was little room to get anything through the doorway. Though believe me - having a little workshop next to the garage is so useful. Cue gratuitous shot of my garage......<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCs4gRFaxamrn12iu3xsIV4mO6e20uJLaGhkwLxMxIL3vwhR3Jcs1BfpKtsEdlYnBaGdfXO34WfkKutne-P1akCCJN1KTmRH4VYHWrpl89r3BlZ6ADY7fhkUWUPL93n9KTi0V9s5_hp8gDzosDPglkjGE0vdByE0J4tZWr-fgYNKwcYT6d68rLSd_o/s3264/car%20in%20garage_August%202020.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCs4gRFaxamrn12iu3xsIV4mO6e20uJLaGhkwLxMxIL3vwhR3Jcs1BfpKtsEdlYnBaGdfXO34WfkKutne-P1akCCJN1KTmRH4VYHWrpl89r3BlZ6ADY7fhkUWUPL93n9KTi0V9s5_hp8gDzosDPglkjGE0vdByE0J4tZWr-fgYNKwcYT6d68rLSd_o/w400-h300/car%20in%20garage_August%202020.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Garage.... and workshop beyond</span><br /></td></tr></tbody></table>First of all, the
car had to be moved back out of the garage to make the room needed to
wheel the engine through from next door...... I removed the rear spheres and popped a
couple of short broom handle lengths in the the rear cylinders to hold
the rear suspension up. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5Kz8RFNCWap1wmNyiA8AnHDCAgaOd7Kmem-9T00atUQolEyIZivcLuoCQkHgOZUZakewoAkhza1sRRl6QkfI_4Zuj7PAKFjpYkfHwfu36s7cOF5bXqKv9QIEtznStVZslbL_lEuLd7r6dsTOUP1eHBdMWNc82kGGQI8g20tFVNKXU8B7QLSn7d62U/s3264/Suspension_rods%20for%20propping%20suspension.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5Kz8RFNCWap1wmNyiA8AnHDCAgaOd7Kmem-9T00atUQolEyIZivcLuoCQkHgOZUZakewoAkhza1sRRl6QkfI_4Zuj7PAKFjpYkfHwfu36s7cOF5bXqKv9QIEtznStVZslbL_lEuLd7r6dsTOUP1eHBdMWNc82kGGQI8g20tFVNKXU8B7QLSn7d62U/w400-h300/Suspension_rods%20for%20propping%20suspension.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Wooden rods used to prop up the suspension</span><br /></td></tr></tbody></table>With
that done I was able to inflate and fit a couple of (very) old rear
wheels/ tyres and remove the axle stands. I didn't fit the front wheels.
I was worried that the rotation of the 'limp' drive shafts (no engine fitted yet) would tear my newly fitted drive shaft gaiters on the chassis. So, instead, I just raised a trolley jack under the beam that goes across the
engine bay and used that to help move the car the three or four feet
needed. <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">My home made engine stand was wheeled out of it's corner in the workshop. </span></span><span style="font-family: arial; font-size: small;"><span>It had been in there so long. Years. </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-zSpvIkKVbbjG8sPqjtnFw2tYfzGki_5oYFsNsPc-tgJbvWvGVIcIhiNyjJQo9PfN70SJftS79ryLeHx4vn2ze1Kb7VruQ-R_FOJk_lGxNlTNAlWrTUbDeycyJUTbd9dHqvv_U6SRxnRjr9o9IyTa4n4F5einWWb9H_VHBglNPnHW4KsuxaDUObAh/s4032/IMG_6988.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-zSpvIkKVbbjG8sPqjtnFw2tYfzGki_5oYFsNsPc-tgJbvWvGVIcIhiNyjJQo9PfN70SJftS79ryLeHx4vn2ze1Kb7VruQ-R_FOJk_lGxNlTNAlWrTUbDeycyJUTbd9dHqvv_U6SRxnRjr9o9IyTa4n4F5einWWb9H_VHBglNPnHW4KsuxaDUObAh/w400-h300/IMG_6988.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">My homemade engine stand had served me well</span><br /></td></tr></tbody></table>My trolley had rubber tyres on it's castors and I'd found
that the combined weight of the engine and gearbox squashed the tyres
and made the trolley nearly impossible to move. That was one of the
reasons I'd delayed fitting the brakes to the engine; to keep the weight
down! With some difficulty and a number of 'three-point turns' I navigated the doorway to the garage</span></span><span style="font-size: small;"><span style="font-family: arial;">. I felt like NASA moving a Saturn V to the launch pad! </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Temporarily swapping places with my compressor, for the first time in many years the engine and car were back in the
same room. With the trolley jack under the front of the chassis again, I moved the car back into the garage. In hindsight it was VERY high risk as the car could easily have
fallen off that jack and damaged itself - if not me. As it was, I got
away with it. </span></span><span style="font-family: arial; font-size: small;">The front of the car was put back on</span><span style="font-size: small;"><span style="font-family: arial;">
axle stands while I did the last few jobs to the engine. </span></span><span style="font-family: arial; font-size: small;"><span>With tomorrow being the
'big day' when I planned to put the engine back in the car, those brake calipers had to
be fitted......</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><b>Brake Calipers</b></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">There is a bit of a technique to fitting the callipers to the car. </span></span><span style="font-family: arial;">With the engine out of the car the brake callipers are fast and easy to fit. That's right: I didn't find time to take any photos...... I'll have to use some scrounged images.</span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">The procedure for refitting the callipers is covered in Operation DX.451-1 in manual 518. Some PDF copies of manual 814, have a similar operation - Operation DJ.451-1 included in volume 2. Other than 'DJ' being for manual gear change cars, the basic process is the same.</span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The units should be bolted the car only hand-tight to start with. </span></span><span style="font-family: arial; font-size: small;">I
must have fitted the discs over the half shafts, then slotted the
calipes on. and calipers on I guess. But that really was all I could do
at this stage. </span><span style="font-family: arial;">First scrounged photo coming up.....</span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNX5mJHsLQOpPR5ZwJF7CjSYQgxS1ZYL99vzGnx2tj-bD_TflSUXcnIbG_QKggSzzeZWHoYqMbn387pdUp3SiDdJsdackLx5B72wlexbiO2Osl4_eIEQu1N5SReih7nKyZ7XrqMnzo2sjsxc2SRFple50L6oRmhC_SqjevSk1WYrSESYBl68B0a-Cr/s1427/Scan.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1427" data-original-width="966" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNX5mJHsLQOpPR5ZwJF7CjSYQgxS1ZYL99vzGnx2tj-bD_TflSUXcnIbG_QKggSzzeZWHoYqMbn387pdUp3SiDdJsdackLx5B72wlexbiO2Osl4_eIEQu1N5SReih7nKyZ7XrqMnzo2sjsxc2SRFple50L6oRmhC_SqjevSk1WYrSESYBl68B0a-Cr/w271-h400/Scan.jpeg" width="271" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;"><span style="font-family: arial;">The securing bolts are ringed</span><br /></span></td></tr></tbody></table></span><span style="font-family: arial; font-size: small;">Until the engine is in the car and all the hyraulics are connected up, I can't finish the fitting: </span><span style="font-size: small;"><span style="font-family: arial;">with the engine running, you need to get someone to apply the brakes.
This causes the pads to contact the discs and (with the bolts only hand
tight), the hyraulic pressure causes the calliper units adjust their
position so that the pads contact the discs 'flat' and evenly. With the brakes still on, held on, the calliper units bolts can be tightened to maintain
that position.</span></span></div></div><div style="text-align: justify;"><p style="text-align: justify;"></p><p style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></p><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><b>Making A Hydraulic Pipe (again)<br /></b></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I hadn't been planning to do this. In
fitting the brake calipers, I found I had to re-make a long and
complicated hydraulic pipe
that went from the 'accelerated idling control' on the carburetor, all the way to the n/s brake caliper. I think it's the pipe for bleeding the left hand side brake. I've marked it on this photo.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhGar8XyJbCkEFi07aA7al1CF1M_mrnzWjXP9CRAkSdcgTi2PbyaRYlPy9Jcl_cjCQJhj69iUo9BEabLU4SdEyunrMZsIE5-amJ9Ih2nidP4wxkkrgzUZX23tr0lENq6aSEv0v9x0LJFJuiZF1Z2J0eI5lsbaQSVR7gbKynpR10sZRhZ-US4rLVGjc/s889/pipe%20to%20caliper%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="601" data-original-width="889" height="270" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhGar8XyJbCkEFi07aA7al1CF1M_mrnzWjXP9CRAkSdcgTi2PbyaRYlPy9Jcl_cjCQJhj69iUo9BEabLU4SdEyunrMZsIE5-amJ9Ih2nidP4wxkkrgzUZX23tr0lENq6aSEv0v9x0LJFJuiZF1Z2J0eI5lsbaQSVR7gbKynpR10sZRhZ-US4rLVGjc/w400-h270/pipe%20to%20caliper%20copy.jpg" width="400" /></a></div> The first one I'd made
had been too short to reach the disc brake caliper!*! The pipe needed to curve around the parking brake caliper without touching it and that meant it didn't then reach the disc brake caliper with enough 'spare to be able to screw in the flare nut. It was short by about 2cm! I've used this photo before, but it shows the pipe in question. <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuIpzEV9ENrzfd3wEMAHZ_uOlkJP_V77HAsxrfR5lCq_VFzW2mklj0p2uz5w7eOX3dOboFwwzeorLDXKyLrdI_JaqXr2AydaTIt0cUQ9s-YgQZzPcUnk0TTqQTi_z_f1jwGo3D4DyiVGHlIJwoDZaOFysgck6KkriPCd4jsSHtOnI40nfZBKiaP1aZ/s1057/parking%20brake%20fitted.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="795" data-original-width="1057" height="301" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuIpzEV9ENrzfd3wEMAHZ_uOlkJP_V77HAsxrfR5lCq_VFzW2mklj0p2uz5w7eOX3dOboFwwzeorLDXKyLrdI_JaqXr2AydaTIt0cUQ9s-YgQZzPcUnk0TTqQTi_z_f1jwGo3D4DyiVGHlIJwoDZaOFysgck6KkriPCd4jsSHtOnI40nfZBKiaP1aZ/w400-h301/parking%20brake%20fitted.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The pipe around the parking brake caliper was too short!<br /></span></td></tr></tbody></table></span></span><span style="font-size: small;"><span style="font-family: arial;">The pipe follows a
complicated route along the side of the block and was threaded behind
other pipes so even more pipework and clips had to come off the car for
me to fit it. It shares a securing sot with the 6.35mm pipe between the pressure regulator and the hydraulic pump. It's not wise to bend and weaken that pipe, so it had to be completely removed to allow me to work on this other pipe....</span></span><span style="font-size: small;"><span style="font-family: arial;">As well as being difficult to remove (stop complaining Paul. It would be harder with the engine IN the car!), as I shaped the replacement, I kept having to do 'trial fits'. <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><b> </b></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><b>Front Engine Crossmember</b></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">With the calipers fitted, I also re-assembled and fitted the front engine crossmember - the beam that goes across the top of the gearbox. The middle of the crossmember is a kind of 'sandwhich' with segmeted (castellated?) rubber half-bushes held to the main beam by two metal half-collars.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9p5wsRjTD84R2p5zfOalkr2IVyD6AAGMY5PF8BPhTcdTOCUpOj2XMC79UNYC1rqg68lM8-p1RyPnUUDUzgq8SfSucSxXjQKyrromjiJb0hNYMuXWtGl8FBOsDntohN8so1kxAy7-GEqYzz4z4LLulsYI-13Yqm59hSBZF5XAJlSG5ZeJ_hqcbgNMR/s1041/engine%20mount%20parts.jpeg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="793" data-original-width="1041" height="305" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9p5wsRjTD84R2p5zfOalkr2IVyD6AAGMY5PF8BPhTcdTOCUpOj2XMC79UNYC1rqg68lM8-p1RyPnUUDUzgq8SfSucSxXjQKyrromjiJb0hNYMuXWtGl8FBOsDntohN8so1kxAy7-GEqYzz4z4LLulsYI-13Yqm59hSBZF5XAJlSG5ZeJ_hqcbgNMR/w400-h305/engine%20mount%20parts.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: small;"><span style="font-family: arial;"><span style="font-size: x-small;">Front engine mount. The rubber 'sandwich' filling is parts 5 and 8 </span></span></span></td></tr></tbody></table>The middle section bolts to the engine/ gearbox and the rubber half-bushes in the sandwich isolates that bolted part from the beam that is bolted to the chassis. In that way, engine vibration and noises is kept from the chassis.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">There are two brackets (numbered '3' in the drawing above) that bolt through the rubber 'daiblos' in the disc brake calipers. That also helps to absorb some vibration.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGVaZXnaRr-CD-UCT1M5BMZkq5g9ImYQy6WVoB4IA-LKCTPmRUNR3j3HEWbfvxQHfBxDL2B5xaBIKkhq99wmOsT3FN6BH6aF6IdbxczmloPDUKKO41TjUzFAWa4jkelsV0WdM5SlXIKKFRNPmJ8nei7QlvTTwvL7V5iyYrfHjrHe9qJI5ubzorPnQR/s3264/IMG_8096.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGVaZXnaRr-CD-UCT1M5BMZkq5g9ImYQy6WVoB4IA-LKCTPmRUNR3j3HEWbfvxQHfBxDL2B5xaBIKkhq99wmOsT3FN6BH6aF6IdbxczmloPDUKKO41TjUzFAWa4jkelsV0WdM5SlXIKKFRNPmJ8nei7QlvTTwvL7V5iyYrfHjrHe9qJI5ubzorPnQR/w400-h300/IMG_8096.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The rubber 'diablos' and bushes in the brake calipers</span><br /></td></tr></tbody></table>Why are they called 'diablos'? It's because the shape is similar to the prop you see jugglers used at circuses and is a kind of Chines yo-yo. No - really! Anyway, the only photos I have of those brackets are some last minute cleaning before repainting, but they look like this.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXikFlLlOgJrpL3qq3aTLaJu2BTfR6Qa0wlqG6J-eY482_mthc7YTAtRvAC71_a469nziXRDvez1jn1zJWjvlXGVKuniuAPIA73mmYTqQi3tLF_HaC1Q78AasxYTrByp3FN_SdPqAV1LkXs7ccWRf8TvQ7Nrj-aNx_RFLASJkZCg9Wq-4gh3jf1PH_/s4032/IMG_7049.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXikFlLlOgJrpL3qq3aTLaJu2BTfR6Qa0wlqG6J-eY482_mthc7YTAtRvAC71_a469nziXRDvez1jn1zJWjvlXGVKuniuAPIA73mmYTqQi3tLF_HaC1Q78AasxYTrByp3FN_SdPqAV1LkXs7ccWRf8TvQ7Nrj-aNx_RFLASJkZCg9Wq-4gh3jf1PH_/w400-h300/IMG_7049.JPG" width="400" /></a></div></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">There aren't many pieces to the crossmember but they do only fit together one way: the engine doesn't sit in the middle of the engine bay and so the sandwich/ collar in the middle is 'handed' - it's not symetrical. If the collar is assembed on the crossmember the wrong way round, then when the assembly is bolted to the engine, the collar will not fit the curvature of the crossmember and it will be at the wrong angle......</span></span></div></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoI1qP4DZIpajeF2qR9yIHXG2wQakpd9rkkF6sdBd0kEGbwktvZZBO8mdhVGTxmviXOMJc0gwSJbFNmNylq9A-X-l2Eh-BAg8GiePDmfmpi-qoLF3sn4GGbgUR9YbVQR9VBPu-ZzvUfhrCij94sXVpr-naE7kDVydaiE8syZfa6xFEInxXDzPZ_uvE/s2015/Wrong.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2015" data-original-width="1120" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoI1qP4DZIpajeF2qR9yIHXG2wQakpd9rkkF6sdBd0kEGbwktvZZBO8mdhVGTxmviXOMJc0gwSJbFNmNylq9A-X-l2Eh-BAg8GiePDmfmpi-qoLF3sn4GGbgUR9YbVQR9VBPu-ZzvUfhrCij94sXVpr-naE7kDVydaiE8syZfa6xFEInxXDzPZ_uvE/w223-h400/Wrong.jpg" width="223" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Assembled wrongly.....(photo credit unknown)<br /></span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">This is how it should be.</span></span></div><p style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"></span></span><span style="font-size: small;"></span></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ1DJ3Ds3hrk5BOFZH4aU3a35TVvSq3GgJBXTK0_0WYHowZJkg8-4y_ulULPIMcbvCv1KRcHacKuWi3wnFn_fNW0prG-YVTuGk1izfdmaGfqjxVNIYPjo6nG338DNBNdvZoz-d0imNqv80Rl2D8cREWcGlqYsOtbeX0OLcPqrHKKyQdrpjigszFfqN/s1920/Right.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1920" data-original-width="1080" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ1DJ3Ds3hrk5BOFZH4aU3a35TVvSq3GgJBXTK0_0WYHowZJkg8-4y_ulULPIMcbvCv1KRcHacKuWi3wnFn_fNW0prG-YVTuGk1izfdmaGfqjxVNIYPjo6nG338DNBNdvZoz-d0imNqv80Rl2D8cREWcGlqYsOtbeX0OLcPqrHKKyQdrpjigszFfqN/w225-h400/Right.jpg" width="225" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Corrected! (photo credit unknown)</span><br /></td></tr></tbody></table><p></p><p style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I was wise to this when I assembled mine - meaning I'm free to make a whole bunch of different and unrelated mistakes later on. And I'm sure I will! Anyway, this is mine (admittedly after the engine was back in the car). You can see the two holes that the radiator feet will bolt in to.<br /></span></span></p><p style="text-align: justify;"></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhp8H_Wr63_eveF3z1mVNUnWDl2702s9YkRjxZMtIte3HsZVfjK_JOq8nfgsi7lwj_Apy7te4zEg8tLYihT-e-8xXQZyEe-xpCqt2ERFbXeU0uo8qN5nv5Yk_vZW1bipvbwrZvfvu_sOboyiuSrSIUe16eTjc2OOeZMSp_gUYOzg6N_7LPnFLhh7-7A/s4032/IMG_7510.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhp8H_Wr63_eveF3z1mVNUnWDl2702s9YkRjxZMtIte3HsZVfjK_JOq8nfgsi7lwj_Apy7te4zEg8tLYihT-e-8xXQZyEe-xpCqt2ERFbXeU0uo8qN5nv5Yk_vZW1bipvbwrZvfvu_sOboyiuSrSIUe16eTjc2OOeZMSp_gUYOzg6N_7LPnFLhh7-7A/w400-h300/IMG_7510.JPG" width="400" /></a></div><span style="font-size: small;"><span style="font-family: arial;">As
well as the brackets providing the holes for the radiator feet, t</span></span><span style="font-size: small;"><span style="font-family: arial;">he
left hand end of the crossmember also provides the location for bolting the
LHM reservoir support to.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhX0PDzuaJWQLshi0gJ6OXw0VUNgREiErciegjMUcXnVbrKnbEfnfT9h2-RxwoPBC_ZlsrApHecF8zufaJhatsoJsa3Axx1O-82Tum6e62gCrNqj2F_QVicNasPyvHMehLGs6ZZUsBQD90X9vd25xkUud3gNctznTkYX5KCMALm5sbXAlMqC5glzsfV/s4032/Reservoir%20support.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhX0PDzuaJWQLshi0gJ6OXw0VUNgREiErciegjMUcXnVbrKnbEfnfT9h2-RxwoPBC_ZlsrApHecF8zufaJhatsoJsa3Axx1O-82Tum6e62gCrNqj2F_QVicNasPyvHMehLGs6ZZUsBQD90X9vd25xkUud3gNctznTkYX5KCMALm5sbXAlMqC5glzsfV/w400-h300/Reservoir%20support.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The resrvoir support bolts to the welded nut here</span><br /></td></tr></tbody></table>And on my 1968 car, the right hand end of the
crossmember is also the fixing point for the front leg of my battery tray.</span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8wNhanuVTyEyQ8itfzBk0PRZHoQ9rlRienQnyU-baegGHG4ltk0f6Cg5Pv6cRNx5j7QfEzqMAG8B8pK4plTjufOVqHIhTdrbo50JnAiC2lcztzL_nUO2ezk4wn1iN13eYSnc6KSDZepmqV-J1okOA6wcZxNOIjpcgJrgPfatsHTsno9MNOJzyG7uA/s4032/battery%20tray%20support.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8wNhanuVTyEyQ8itfzBk0PRZHoQ9rlRienQnyU-baegGHG4ltk0f6Cg5Pv6cRNx5j7QfEzqMAG8B8pK4plTjufOVqHIhTdrbo50JnAiC2lcztzL_nUO2ezk4wn1iN13eYSnc6KSDZepmqV-J1okOA6wcZxNOIjpcgJrgPfatsHTsno9MNOJzyG7uA/w400-h300/battery%20tray%20support.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">On my 1968 car, the battery tray goes here</span><br /></td></tr></tbody></table> So many more jobs and milestones are going to be possible once the engine is in! <br /></span></span></div><br /></div></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-10690949487809915072023-07-08T14:38:00.042+00:002024-02-18T17:12:19.142+00:00Parking Brake Mechanisms - Stripdown and Overhaul<div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">In the build up to dropping the engine in, I've been doing a few small last minute jobs. In some cases these are things I forgot I would have to do!</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5RNCx1uFkR5jbqHWJNiLH-P3oFIJPejioovK1HXbJ6skfPttxiUo4tpWyWoHpbbCHr15ecGXRDFwkMU6iH_N4RpYJ6RYdDSijkek8lsE1vPBc91btNv94P_Jq7a6kA_nneeYyLI1XtwuvINQyhHWGKqisQf7k7ewP8ZrdA9PKGHyErzcQ-jUbhmlr/s1057/parking%20brake%20fitted.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="795" data-original-width="1057" height="301" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5RNCx1uFkR5jbqHWJNiLH-P3oFIJPejioovK1HXbJ6skfPttxiUo4tpWyWoHpbbCHr15ecGXRDFwkMU6iH_N4RpYJ6RYdDSijkek8lsE1vPBc91btNv94P_Jq7a6kA_nneeYyLI1XtwuvINQyhHWGKqisQf7k7ewP8ZrdA9PKGHyErzcQ-jUbhmlr/w400-h301/parking%20brake%20fitted.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Parking brake unit refitted</span><br /></td></tr></tbody></table>I was so 'in the zone' that I didn't really take any photos of this job. There's not much to it but some photos might have helped to demystify things. I've had to use photos from all over the place. Dago Langen has been particularly kind in letting me use the photos that he took. I'm glad one of us remembered!<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">For some reason, replacement of the calipers wasn't included in the '814' repair manual. But if you are lucky, it might have been added to your PDF version of manual 814. If so, it will be at section 1 in volume 2 and shown as Operation DX.454-1. If it's not there,</span></span><span style="font-size: small;"><span style="font-family: arial;"> it can be found at Operation DX.454-1 in manual 518.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Even when you find it, you will see it just that - replacement of the calipers. Off and back on. It doesn't go any deeper than that. For example on changing the pads and fitting the anti-rattle springs.There aren't many parts, but it can be confusing trying to put them all back together.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhd4jq7uKyKhXFmcx4QkhTd4_7KwH_CTCe29sdqPAxwO83lGhu8l9w_gMhjYKDVJ6RsIlQLt0fsjasAEAjgCd0LfHee3O22ylG08y2e1z83OB5c1x-2T1aY_RwknhzvA_Ugiy0SXrcdS0ecG0cUr6OMWu5MoblZoPHJ7yPGUOju3vfWwVU7iBW7PJjT/s1045/parking%20brake%20mechanism%20parts.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="796" data-original-width="1045" height="305" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhd4jq7uKyKhXFmcx4QkhTd4_7KwH_CTCe29sdqPAxwO83lGhu8l9w_gMhjYKDVJ6RsIlQLt0fsjasAEAjgCd0LfHee3O22ylG08y2e1z83OB5c1x-2T1aY_RwknhzvA_Ugiy0SXrcdS0ecG0cUr6OMWu5MoblZoPHJ7yPGUOju3vfWwVU7iBW7PJjT/w400-h305/parking%20brake%20mechanism%20parts.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Exploding diagram of the parking brake mechanism</span><br /></td></tr></tbody></table></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">On each side of the car, a pair of log arms (part 4) pivots on a shaft that is part of the caliper body. The brake pads (3) are fitted to the top half of the arms and when the cable pulls the arms together, it pulls the pads on to the disc. Strong springs (5) fitted to the cable push the arms apart again once the brake is released.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"></span></span><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiihdgfpc0-o4x1coktL2aLyirIReDoyRA2Q-NrRAChPulEoKNv7EbNET394nv7ZMmOEEveUrnNKl1IvFpmtRWnnKLSK5snuKeaUv_58maMJlnonh2snpPEcTXsPlQoMWen5_0O2kjKgHhEFPEXcxP0alNE_JD4_-v1tyGJBXI-lSNJa5qru9xk1jro/s2048/283713997_3111373899124237_6609808042488800303_n%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2048" data-original-width="1536" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiihdgfpc0-o4x1coktL2aLyirIReDoyRA2Q-NrRAChPulEoKNv7EbNET394nv7ZMmOEEveUrnNKl1IvFpmtRWnnKLSK5snuKeaUv_58maMJlnonh2snpPEcTXsPlQoMWen5_0O2kjKgHhEFPEXcxP0alNE_JD4_-v1tyGJBXI-lSNJa5qru9xk1jro/w300-h400/283713997_3111373899124237_6609808042488800303_n%20copy.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The cable pulls the arms together (photo: Dago Langen)</span><br /></td></tr></tbody></table><span style="font-family: arial;">There
is a bolt and lock nut through each arm to adjust the brake pads (not numbered in the diagram).
These are VERY difficult to access when the engine is in the car.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilNSvI4HWaiSjCUv-Uk3NxjJuiO9XozCHagcw9xsCT8jgamcoQph6J9hVQAQE95FKRuzPOIo-_RhN4uSvDiMyOq-Zzw2V6_mjOkprdctDqv7iubY6CZQlA8nX1JaASPlxnHRRCWvop_DuykC4-jqn4Eo-4zeF5OebxTu0_iGanfaC9R2P0M-X5k3i4/s4032/IMG_8065.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilNSvI4HWaiSjCUv-Uk3NxjJuiO9XozCHagcw9xsCT8jgamcoQph6J9hVQAQE95FKRuzPOIo-_RhN4uSvDiMyOq-Zzw2V6_mjOkprdctDqv7iubY6CZQlA8nX1JaASPlxnHRRCWvop_DuykC4-jqn4Eo-4zeF5OebxTu0_iGanfaC9R2P0M-X5k3i4/w400-h300/IMG_8065.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The adjusters are awkward to access from any angle - even under the car</span><br /></td></tr></tbody></table>To hold the pads steady on the arms, each pad has a slot at one end that locates onto part of the main caliper body. </span></span><span style="font-size: small;"><span style="font-family: arial;">That's
really just to stabilse the arm and so the pad and arm pivot slightly. The pad needs to be able to move without it's slot binding or catching. To
stop each pad rattling as you drive along, 'anti-rattle springs' (3)
are fitted in the slots.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">It's not an issue for me as my car is a 'proper' left hand drive car, but the 1968 parts catalogue shows that
for a right hand drive car, there are a combination of three differnt
lever arms used: a pair and two that must be handed......Other
catalogues show different combinations of parts. The bottom line is
that, if you have a RHD car, be careful you don't muddle your lever
arms!</span></span><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjluaZ2vUfecFEGh9i5c_4zI66LEeHjjyc5eWLTgb1Fz7cj1OvBwy3xAgUhPWktEPlsPBVHiq9qXPO9fDtIvx8vAv5_25myM3qs9fd9U5JPIakjHsYaU3iIiRChY57wy-rMaQdDpQa_nq8zJSeP25KLd9djwpGRsIgDCrh30mX7AXolaTCaOUOxlu1p/s998/pivot%20arm%20parts.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="169" data-original-width="998" height="109" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjluaZ2vUfecFEGh9i5c_4zI66LEeHjjyc5eWLTgb1Fz7cj1OvBwy3xAgUhPWktEPlsPBVHiq9qXPO9fDtIvx8vAv5_25myM3qs9fd9U5JPIakjHsYaU3iIiRChY57wy-rMaQdDpQa_nq8zJSeP25KLd9djwpGRsIgDCrh30mX7AXolaTCaOUOxlu1p/w640-h109/pivot%20arm%20parts.jpeg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;"><span style="font-family: arial;">The part numbers show that, for RHD cars, the lever arm parts are 'handed'</span><br /></span></td></tr></tbody></table></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The calipers of my car had been removed, dismanted, cleaned and primed when? 2015? Probably! Mine weren't quite as mucky as these, but you can see how the road muck can easily stop the brake mechanisms working as intended.</span></span><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOkM9g8ZPTZcKQbaDHGyLF7m57K_d_g4SzS8lWokCrKDcLi8wfw-T1IffOzjKpoTWtTIh6oxy5QllzMcfBhxeLpwiFYLJSLuC8CVyIjHRMxXWx-W_Y2Qvi_wtDg0EL-eM8lZaH8MKLAcdGYEbeEI8RG9XI-KhFmBGj_qlqmuP9xQ4pendgYKF1-0y_/s1440/271655413_1631230457232411_6940703368011358829_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1440" data-original-width="1440" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOkM9g8ZPTZcKQbaDHGyLF7m57K_d_g4SzS8lWokCrKDcLi8wfw-T1IffOzjKpoTWtTIh6oxy5QllzMcfBhxeLpwiFYLJSLuC8CVyIjHRMxXWx-W_Y2Qvi_wtDg0EL-eM8lZaH8MKLAcdGYEbeEI8RG9XI-KhFmBGj_qlqmuP9xQ4pendgYKF1-0y_/w400-h400/271655413_1631230457232411_6940703368011358829_n.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Parking brake unit removed (photo: Dago Langen)</span><br /></td></tr></tbody></table><span style="font-family: arial;">It's hard to see, but there is a split pin on the end of each shaft. When those are taken out, the arms can be removed. And with the arms out of the way, the brake pads can be removed. You might find that small 'anti-rattle spings' also fall out.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiX-bbfMQqIle9MoL3AChGARn7snW771WUFClXmsG_Aj6wMfYnGv6LoV-9jwsfwte8_ZIs-dQR4v_EEe_QyBtF5fMJBiT0A0cmx3bTM5CF4Z7peJ3Qk61Kxx16lqaFFV0RbBN5ul8XoOMt9LFKliMRKQvLaNmwjLN66vUQe4gdEgNfhh6VkT15PB8NT/s4032/IMG_8062.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiX-bbfMQqIle9MoL3AChGARn7snW771WUFClXmsG_Aj6wMfYnGv6LoV-9jwsfwte8_ZIs-dQR4v_EEe_QyBtF5fMJBiT0A0cmx3bTM5CF4Z7peJ3Qk61Kxx16lqaFFV0RbBN5ul8XoOMt9LFKliMRKQvLaNmwjLN66vUQe4gdEgNfhh6VkT15PB8NT/w400-h300/IMG_8062.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;"><span style="font-family: arial;">Parking brake 'anti-rattle' springs</span><br /></span></td></tr></tbody></table></span><span style="font-size: small;"><span style="font-family: arial;">All the parts were degreased and any rust was removed. I paid particular attention to the shafts that the arms pivot on. as well as the bosses that the slots of the pads fit over. </span></span><span style="font-size: small;"><span style="font-family: arial;">I bulk-sprayed some parts it included parking brake parts, even though I didn't assemble them at the time. <br /></span></span></div></div></div></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I cleaned up the threads of the adjuster bolts. These bolts are fairly specialised in that the hex head is very shallow. I suppose that if you needed such a bolt, you could grind down the head of a standard bolt.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The pads are the first things to be fitted. The pads I'd removed from mine back then were hardly worn but I was worried about them having oil or LHM on the surfaces. </span></span><span style="font-size: small;"><span style="font-family: arial;">By
chance someone was selling an unwanted new set at the D rally in June
this year and so I bought those. I think that was probably the nudge I
needed to remind me I still needed to do this job. <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjm5H4J7YIO0E16IAnbS-5F5HyUI2GZhiNQ1klgeYHiVPHUFPml8wzzF-ReZATrb4A5m7d7AagM7wC2zT2sbhnxtknh8oVpL993MyBaMG9xWlbyYbD6FFFfFf_mhZxWNbdDI121SRxn5Fm6n6d5Qw_yKhinKd6yfKyu70IL5NtEpBhflAbIKXvH48aX/s4032/IMG_8060.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjm5H4J7YIO0E16IAnbS-5F5HyUI2GZhiNQ1klgeYHiVPHUFPml8wzzF-ReZATrb4A5m7d7AagM7wC2zT2sbhnxtknh8oVpL993MyBaMG9xWlbyYbD6FFFfFf_mhZxWNbdDI121SRxn5Fm6n6d5Qw_yKhinKd6yfKyu70IL5NtEpBhflAbIKXvH48aX/w400-h300/IMG_8060.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">I chose not to re-se these pads but have hung on to them</span><br /></td></tr></tbody></table></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I put a little copper grease on the bosses that the pads slot on to, just so the pads moved more easily. </span></span><span style="font-size: small;"><span style="font-family: arial;">This partly to allow for ajustment and partly to compensate for
wear - though there isn't really any of that. I winkled the anti-rattle springs back in the gap in the slot. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"></span></span><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUc60e26dadV4YjxgdXYxMLzJA9nFvCWOxCZ6pETV-jzgAQ3c5wRtZ7TaWa0g3c6FoekDsZNY4H-iHiWHF_e2d2QkQ6r7DOqGcNBm4y3JoCCdCdByjZcVrdUzdnyVh5i3x22jgROWZHE5boayET0ytxJ289dd7_43raUSt1DhVS4JegALHFy44uOx0/s1092/Locating%20the%20shoe.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="785" data-original-width="1092" height="288" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUc60e26dadV4YjxgdXYxMLzJA9nFvCWOxCZ6pETV-jzgAQ3c5wRtZ7TaWa0g3c6FoekDsZNY4H-iHiWHF_e2d2QkQ6r7DOqGcNBm4y3JoCCdCdByjZcVrdUzdnyVh5i3x22jgROWZHE5boayET0ytxJ289dd7_43raUSt1DhVS4JegALHFy44uOx0/w400-h288/Locating%20the%20shoe.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Note the anti-rattle spring in the slot (photo: Dago Langen)</span><br /></td></tr></tbody></table></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The factory says there are FOUR anti-rattle springs to a car - that's just one per pad. </span></span><span style="font-size: small;"><span style="font-family: arial;">Because
of the way they fit, it feels odd to only attach a spring to one side of a pad and it's tempting to think that each would have two
(one either side of the mount) but that is
not what Citroen intended, and you will struggle to fit more than one
spring per pad in the slot.</span></span></div></div></div><p style="text-align: justify;"></p><p style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I attached the adjuster bolts to the arms. I put a little grease on
the threads to make them easier to adjust in due course</span></span><span style="font-size: small;"><span style="font-family: arial;">. </span></span><span style="font-size: small;"><span style="font-family: arial;">I wound the
bolts on as far they would go at this stage and only loosely fitted
their lock nuts.</span></span></p><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6F36qDFtWCyVi5VIjt526kKjBQWRXRjRS5TGooaRVOBoAdMGfzvZMRBSUG7Gn3CiN9t16ApjMSJswDzcQd8hnikQ1ppiP2gQk3Ce-Dk3uJidu9xi62Kvrh7ndh4z1DAxLAglF-TNUU0WdRfEuHM8ubSJiORoJBfKz4w4sMlLvPhAxWy31dMUfpdJV/s2048/283969315_3111374029124224_2067212427290109493_n%20copy%202.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2048" data-original-width="1536" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6F36qDFtWCyVi5VIjt526kKjBQWRXRjRS5TGooaRVOBoAdMGfzvZMRBSUG7Gn3CiN9t16ApjMSJswDzcQd8hnikQ1ppiP2gQk3Ce-Dk3uJidu9xi62Kvrh7ndh4z1DAxLAglF-TNUU0WdRfEuHM8ubSJiORoJBfKz4w4sMlLvPhAxWy31dMUfpdJV/w300-h400/283969315_3111374029124224_2067212427290109493_n%20copy%202.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Adjuster bolts (photo: Dago Langen)</span><br /></td></tr></tbody></table></span></span><span style="font-family: arial; font-size: small;"><span>The arms were fitted on their shafts. </span></span><span style="font-size: small;"><span style="font-family: arial;">It's important that the lever arms can pivot freely. I found that with my enthusisatic painting, they were sticking on the pivots, so the pivots and the holes through the arms got a rub down with emery cloth. The parts books show that the levers have a bush going through them (part 7 in the diagram above), but I didn't notice them on my parts. Perhaps they are pressed in? Happy that the arms moved freely, and that the pads could slide on their bosses, I </span></span><span style="font-size: small;"><span style="font-family: arial;">fitted the split pins to secure the arms in place. </span></span><br /></div><span style="font-size: small;"><span style="font-family: arial;"> </span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Before fitting the calipers to the bellhousing, I used carb cleaner to clean the pad surfaces, and the disc brakes. I offered up the calipers, slipping them over the disk brakes, </span></span><span style="font-size: small;"><span style="font-family: arial;">and put the securing bolts on just hand tight at this stage</span></span><span style="font-size: small;"><span style="font-family: arial;">. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">While I had the opportunity, I adjusted the pads with the adjuster bolts so that they just contacted the disc brake. The manual says there should be a 0.1 mm gap between the disc and pad. I tried that but bcause of 'run out' on the discs ('warp' if you will) a 0.1mm clearance at one point left the pad rubbing when the disc was rotated. So I adjsuted my pads so that, when the disc was rotated, the pads *just'* cleared the disc in all places. I didn't tighten the locking nuts just yet.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The manual says that the order of jobs should be:</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">- Loosely fit the calipers</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">- Fit the parking brake cable and springs</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">- Tighten the calipers</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">- Adjust the pads</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">- Check the cable adjustment.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The only problem was that my engine was out of the car - so I couldn't fit the cable just yet so needed to skip that. You don't want the caliper bodies to rub on the rims of the discs. The workshop manual says that there should be a gap of 4mm between the edge of the disc rim and the arch of the caliper body. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh80_o-Ct4DwyoWfxQhxXnCbz_E1U3gvS1DlOkCUjFuFknvd6VegOMkB0BD-WRJtVFMAztoRTkQpq46rxYS7XsHvDylHgaDLxvEKS06XT0qzZgnA1wUvv_sIVUHOL2Ns9jw9n1kn6xkoEGA3slq7F8uDUUz2AfNzNVMMfahSJIh2ldgdQ6AFS5C8PFT/s2048/283713997_3111373899124237_6609808042488800303_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2048" data-original-width="1536" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh80_o-Ct4DwyoWfxQhxXnCbz_E1U3gvS1DlOkCUjFuFknvd6VegOMkB0BD-WRJtVFMAztoRTkQpq46rxYS7XsHvDylHgaDLxvEKS06XT0qzZgnA1wUvv_sIVUHOL2Ns9jw9n1kn6xkoEGA3slq7F8uDUUz2AfNzNVMMfahSJIh2ldgdQ6AFS5C8PFT/w300-h400/283713997_3111373899124237_6609808042488800303_n.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Caliper assembly fitted (photo: Dago Langen)</span><br /></td></tr></tbody></table>I followed Dago's lead: the easiest way to set the gap is to gently wedge a screwdriver in between the disc edge and the brake unit......</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEBNfB991EM8uLQ4s9LydHEYpsxU17qtWHJDfxKTxSjUxhXe1AWvHvibSRaiKCeb_KJGhF5Q3ReZ4-b9CmDa1OmZkOETiM6WAVmHdcaMS2T4khBLlIiRxn_-eqjrSotQzDzxp2euX00-koLHFE6LK7uoGJQUM5SdlrhLaaljfSk9YkOp66eleaRL_3/s2048/284095158_3111373902457570_1523432682719240001_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2048" data-original-width="1536" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEBNfB991EM8uLQ4s9LydHEYpsxU17qtWHJDfxKTxSjUxhXe1AWvHvibSRaiKCeb_KJGhF5Q3ReZ4-b9CmDa1OmZkOETiM6WAVmHdcaMS2T4khBLlIiRxn_-eqjrSotQzDzxp2euX00-koLHFE6LK7uoGJQUM5SdlrhLaaljfSk9YkOp66eleaRL_3/w300-h400/284095158_3111373902457570_1523432682719240001_n.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Make sure there is a gap before tightening the caliper units (photo: Dago Langen)</span><br /></td></tr></tbody></table>.....while tightening the brake unit bolts. The bolts needed to be tightened to a torque of between 10 and 11m.kg.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVjxw4yMIZQ90v9NU3qS-0yjWSufQRpFsYwO2UA8xwBkVrzVCu-P9Hz79p1vnpGgiAIWleORA4S2RwzYTA_7fRcF9yiyxYQY5-q2L5TTZHI80qJvCmtv1r0maLzztBmGby_ocpPQa4XkZSCdNZXYA7eHgtNv1-60BG8_af3xWBiHozvj-x0RkgVrWY/s2048/283891976_3111373879124239_3273322972776210619_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2048" data-original-width="1536" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVjxw4yMIZQ90v9NU3qS-0yjWSufQRpFsYwO2UA8xwBkVrzVCu-P9Hz79p1vnpGgiAIWleORA4S2RwzYTA_7fRcF9yiyxYQY5-q2L5TTZHI80qJvCmtv1r0maLzztBmGby_ocpPQa4XkZSCdNZXYA7eHgtNv1-60BG8_af3xWBiHozvj-x0RkgVrWY/w300-h400/283891976_3111373879124239_3273322972776210619_n.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Tightening the brake units (photo: Dago Langen)</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">Once the caliper units were in place I re-checked the adjustment of the pads. When setting the adjustment, the manual says that the caliper arms should be pulled together. I checked and made a couple of adjustments. Maybe I was fussing, maybe the calipers had settled in a different spot. I checked that everything moved as intended and that was that for the moment.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I won't be able to refit the operating cable and springs until the engine goes back into the car - that's happening tomorrow!<br /></span></span></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-80606381738013584472023-06-30T07:03:00.009+00:002024-01-16T16:51:20.211+00:00Drive shafts and hubs<div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> Just a quick one this, although I did do it very gradually and over the course of a year or so.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnG9wrE02OECPePYp9OTo3U0hpruZrk0cstbjfn8PicJUwhGhJQVH_wQ6ta475l6s3ykhYl8iZ64j5YRQr6cnhPBo2N2MAuyCRwxgWvVU0VHTeDwS4vOqYXIFfsVa_Z2KvUcm8r1o_k0JSkZJMYFyfK5_hDf113-6CCEI-Sqdyzdg23Rjltm3r68b3/s4032/IMG_7279.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnG9wrE02OECPePYp9OTo3U0hpruZrk0cstbjfn8PicJUwhGhJQVH_wQ6ta475l6s3ykhYl8iZ64j5YRQr6cnhPBo2N2MAuyCRwxgWvVU0VHTeDwS4vOqYXIFfsVa_Z2KvUcm8r1o_k0JSkZJMYFyfK5_hDf113-6CCEI-Sqdyzdg23Rjltm3r68b3/w400-h300/IMG_7279.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Drive shaft (and engine!) refitted</span></td></tr></tbody></table></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">As my car is from 1968, it has aluminium tri-ax housings. The size of these means that the drive shafts cannot simply be pulled out through the middle of the hubs. Instead, you first need to remove the ri-ax so that you can remove the aluminium housing. I did that back in April 2020 and you can read about it <a href="https://ds-restoration.blogspot.com/2020/04/tri-axle-removal.html" target="_blank">HERE</a>.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhObdeQpV10Hdy0hjaxu4FsMfP51Wuqy4gTn1vJit1Zm78I7KweDbGW0Gm768EYHmz11YJGps7YQdy69MNA4fhynT3bEJI7viS42LKMtj5bPcQljgMWHvODvGJFYPL_z3s6L7L_M2gEBF51Vjm_0mSLZGqummrBHL0mzaTiN8dJNO0jO0v2PPzIPH-J/s3264/IMG_0571.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhObdeQpV10Hdy0hjaxu4FsMfP51Wuqy4gTn1vJit1Zm78I7KweDbGW0Gm768EYHmz11YJGps7YQdy69MNA4fhynT3bEJI7viS42LKMtj5bPcQljgMWHvODvGJFYPL_z3s6L7L_M2gEBF51Vjm_0mSLZGqummrBHL0mzaTiN8dJNO0jO0v2PPzIPH-J/w300-h400/IMG_0571.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Tri-ax removal</span><br /></td></tr></tbody></table> A common problem you find on Ds is that people over-greese through the
nipple at the hub end of the shaft. This provides grease to the double
Hook joint. They are apparently "greased for life" - so why have a
grease nipple at all? Well the grease nipple doesn't directly feed the
bearings apparently. It just supplies a little grease that gets thrown
around the joint to help lubricate it. If you over-grease, all that
happens is that you end up with grease sprayed all over the inside of
the wheel rim. And wider if it's seriously over-greased.</span></span></div><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgngskQ_X7Szi6PxuMBdHJXIQ6chhxRX5-A1AQDydQikU0DhVrWPMyJT1OtptfKesyDfjxcx_TE8BTQulvPnYLsx-nX5_hsseFIU8MIApQWo2iM6X0OLH2SX5XwVIWy_eeokOpmF4ASmeigYZXIvpFlHMhmRwq7hlcQgTKwNplU2_iEDifsH-35eoMn/s4032/IMG_7223.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgngskQ_X7Szi6PxuMBdHJXIQ6chhxRX5-A1AQDydQikU0DhVrWPMyJT1OtptfKesyDfjxcx_TE8BTQulvPnYLsx-nX5_hsseFIU8MIApQWo2iM6X0OLH2SX5XwVIWy_eeokOpmF4ASmeigYZXIvpFlHMhmRwq7hlcQgTKwNplU2_iEDifsH-35eoMn/w400-h300/IMG_7223.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">An over-greased Hook joint.....the nipple is by the Ligarex strap<br /></span></td></tr></tbody></table></span></span><span style="font-size: small;"><span style="font-family: arial;">Perhaps
part of the problem is that people think the whole joint - and the rubber gaiter - needs to be
filled with grease. It doesn't. The space is there within the joint to allow it to flex, and the gaiter is really just a dust and grit shield.
My wheel rims were coated, so I knew I needed to remove excess grease
from my joints. I
laid each shaft out on a sacrificial plastic sheet and then used
compressed air to loosen and force out any excess grease. I used a
spatula to scoop out gloops of grease. I removed most of what I could
but left a little there. Hopefully there is so little that it won't
spray everywhere once the car is on the road. <br /></span></span><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">While I'm on this themes, </span></span><span style="font-size: small;"><span style="font-family: arial;">I
don't know why, but Citroen seem to be very stingey with their grease
nipples. The hubs and shafts have one grease nipple each, and then plugs
(looking like slotted screws) where the other nipples fit.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBba3iVye8lk16LFO6cVSMeK--5c8ur8T_GJmIDCuNjJqJ5xBqfV5g7du4xWJ6Acd1FPZ5gB2DHa2gN3z7odyJhGocM7YvBDJFcX7xTr5EwCVUMGVx_Nx2aEexwtfN5BDSaEaJY5bNCsM-aVvlksVBwIFc-Y54A_nY6ZhFa8hlGC103u6ORw2Z40GJ/s4032/IMG_4915%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBba3iVye8lk16LFO6cVSMeK--5c8ur8T_GJmIDCuNjJqJ5xBqfV5g7du4xWJ6Acd1FPZ5gB2DHa2gN3z7odyJhGocM7YvBDJFcX7xTr5EwCVUMGVx_Nx2aEexwtfN5BDSaEaJY5bNCsM-aVvlksVBwIFc-Y54A_nY6ZhFa8hlGC103u6ORw2Z40GJ/w400-h300/IMG_4915%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A plug and a grease nipple</span><br /></td></tr></tbody></table>They
are proper 'things' and are in the parts
catalogues, though not shown as being fitted to the shafts - just the
steering relay arms - part 18 below. <br /></span></span><div><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkR0xABs_M4TpNq_MfHYCOqcaKq98VW4Et94fvbvSAXzfXG_2RHiSxXybJknGdKEJHY4VkihXydvkRgW1WL5SYoO_vq8nslV5EahvwKgzjGZ-O2G_sNZOdXCtYT_5TrV9Lup66KL85roc-3kdzR1luTe4MgfK3lylfF7STQckeGIY30eA7dVYHdBP1/s1112/plug%20screws.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="435" data-original-width="1112" height="156" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkR0xABs_M4TpNq_MfHYCOqcaKq98VW4Et94fvbvSAXzfXG_2RHiSxXybJknGdKEJHY4VkihXydvkRgW1WL5SYoO_vq8nslV5EahvwKgzjGZ-O2G_sNZOdXCtYT_5TrV9Lup66KL85roc-3kdzR1luTe4MgfK3lylfF7STQckeGIY30eA7dVYHdBP1/w400-h156/plug%20screws.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Plug screw instead of a grease nipple: part 18</span><br /></td></tr></tbody></table></span></span><span style="font-size: small;"><span style="font-family: arial;">I also found that for each pair of
ball joints on the hubs, there was one grease nipple and one screw.... </span></span><span style="font-size: small;"><span style="font-family: arial;">The
idea is that (when you want to grease the car) you remove the plug,
borrow a nipple from wherever it's fitted, grease, and then put the plug
(and nipple) back...... I couldn't be doing with all that, and decided
to remove
the plugs and fit extra grease nipples. I'm sure you can pick them up
anywhere but, (being a bit anal!) I bought some original Citroen grease
nipples. They were 2 Euros for eight of them - so hardly expensive.<br /></span></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHBbclV6GiiETFWS6kmPjLOT6BlCxGJdHaxjCifbPQaRA-uuh_mFK00Eja1KHD3Ns7VDJZL-zukusDxQSw_1rM2zocMPdD2RN2jVe2I85pxbHfMVe4uDqB01xIr25-LdRzQNE69-9sXhVquqLWbbF96BrIRiZi_2trsv4tm2ctTNI_5iSaQeAHkLut/s4032/IMG_7220.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHBbclV6GiiETFWS6kmPjLOT6BlCxGJdHaxjCifbPQaRA-uuh_mFK00Eja1KHD3Ns7VDJZL-zukusDxQSw_1rM2zocMPdD2RN2jVe2I85pxbHfMVe4uDqB01xIr25-LdRzQNE69-9sXhVquqLWbbF96BrIRiZi_2trsv4tm2ctTNI_5iSaQeAHkLut/w400-h300/IMG_7220.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Who says 'new-old-stock' parts have to be expensive?</span><br /></td></tr></tbody></table><span style="font-family: arial;">More recently, I cleaned up and painted the hubs and drive shafts. </span></span><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiK1nwN_VEDLTx5217kXJDlkNteZR5rkqIBJAyJzym5a6bnpIHqPXQkaIXe8DL4W1aHwYOwJ7j8-xivQ7hyRgcTnYFW5rt29QK9H6D8xdwB_HNuqOae_lKyfHnN5UXvwK-WcwiLD3fVBetOYJUQl5fid9K2Q1rMp9YDShYjA4LDOQ7lu7az08VKP_S/s3264/IMG_0796.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiK1nwN_VEDLTx5217kXJDlkNteZR5rkqIBJAyJzym5a6bnpIHqPXQkaIXe8DL4W1aHwYOwJ7j8-xivQ7hyRgcTnYFW5rt29QK9H6D8xdwB_HNuqOae_lKyfHnN5UXvwK-WcwiLD3fVBetOYJUQl5fid9K2Q1rMp9YDShYjA4LDOQ7lu7az08VKP_S/w400-h300/IMG_0796.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A job I'd not been looking forward to</span><br /></td></tr></tbody></table>The hubs were
carefully cleaned up and de-greased. I masked off the ball joints and
the centre, rotating part of the hub and just prepared to paint the
outer cast steel part of the hubs. </span></span></div><div style="text-align: justify;"><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVt7RG3Vu33vtZSxz_kMu9ZhQvO4uIoEaIp-sRRIU2kcez1Ro1dFd_F1R5MLzVBevsa4kq68n9MXzsVAqq3mLOi2desadQhMX2n4e5GVcX2st8TdZEt_GCvqt4D3uUBNBkjuIzTF6SJ2nzF-Maw3Mu8MnVdtZ8EQWAGri4t_Y_S3RpUBwM4tmc1yjy/s4032/Driveshaft%20painting_2.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVt7RG3Vu33vtZSxz_kMu9ZhQvO4uIoEaIp-sRRIU2kcez1Ro1dFd_F1R5MLzVBevsa4kq68n9MXzsVAqq3mLOi2desadQhMX2n4e5GVcX2st8TdZEt_GCvqt4D3uUBNBkjuIzTF6SJ2nzF-Maw3Mu8MnVdtZ8EQWAGri4t_Y_S3RpUBwM4tmc1yjy/w400-h300/Driveshaft%20painting_2.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Degreasing everything took ages.....</span></td></tr></tbody></table></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I was pleased with the results.<br /></span></span></div></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"></span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOZyyRmqOAekcUdeYIpmtPoK6sZ06TMk1-UtXfMeC_XTy_zGt3pYeW2_TElb6ziNl0riMHF8OvV3kOi9vF-aVPjyX_H2j6PqYCzjfIPb9fgoxvwRH1Fa4lm0FT06Ch3KlK5-XS6Xd2OKcdxi0KzRGMKHF8qk_aQJ6EXxmLd-MU6z-mMzBxMGAqvB1P/s4032/IMG_6395.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOZyyRmqOAekcUdeYIpmtPoK6sZ06TMk1-UtXfMeC_XTy_zGt3pYeW2_TElb6ziNl0riMHF8OvV3kOi9vF-aVPjyX_H2j6PqYCzjfIPb9fgoxvwRH1Fa4lm0FT06Ch3KlK5-XS6Xd2OKcdxi0KzRGMKHF8qk_aQJ6EXxmLd-MU6z-mMzBxMGAqvB1P/w400-h300/IMG_6395.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Painting the drive shafts and associated parts </span><br /></td></tr></tbody></table></span></span></div></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I refitted the rubber dust covers over the balljoints of the hub - packing them with grease. You are advised not to put too much grease in, but I think at least two of mine look to 'plump. Removing any excess grease is simply a case of removing the retailning clip and squeezing a little of the grease out from the dust cover. I was re-using the original dust covers. I'd been careful not to tear them when removing the ball joints but could see small holes in them. I fixed these with Superglue. partly because I didn't have any alternative ones to fit and partly because I wanted to keep using the original ones for aslong as I could. I don't trust modern reproduction rubber, and here is why:<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> I'd bought some new triax gaiters several years ago as part of an order from a foreign supplier. The supplier sold cheaper versions of lesser quality</span></span><span style="font-size: small;"><span style="font-family: arial;"> - but they also sold more expensive ones that were supposedly 'best quality'. </span></span><span style="font-size: small;"><span style="font-family: arial;">That's what I paid for. Now I came to fit them I found that the two gaiters for the tri-ax ends were completely different. There are no makers marks that I could see and the moulding seem to be the same, however one was flexible, dull in colour and rubbery. The other was stiffer - more like plastic - and shiny </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH3_qMpwZ5kW9oJyf26Ms4mc9eqZlW7NSrTLJAdVHNnL6PtmJVbmh5oT0B0n7nHF-Hhcl60CRED6NXkgPe2-BDmhMpaDWJQwo1XBgDiObewtD0xwac5MSMDqvWVybSOBzzdupFlZXnm8IWF7Plpp89-DQu3-NKFYcb6fbTt-HT9eEfTyG12aF2hIqx/s4032/IMG_7221.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH3_qMpwZ5kW9oJyf26Ms4mc9eqZlW7NSrTLJAdVHNnL6PtmJVbmh5oT0B0n7nHF-Hhcl60CRED6NXkgPe2-BDmhMpaDWJQwo1XBgDiObewtD0xwac5MSMDqvWVybSOBzzdupFlZXnm8IWF7Plpp89-DQu3-NKFYcb6fbTt-HT9eEfTyG12aF2hIqx/w400-h300/IMG_7221.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Chalk......and cheese</span><br /></td></tr></tbody></table>I concluded that whether by mistake or through laziness, I'd been supplied with one cheap and one expensive - but which was which! I decided to keep the ones I'd bought as spares and start again: I bought new gaiters from Citroen Classics. I think Darrinn said they are made of neoprene and are hard wearling.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I slipped the gaiters, hub and tri-ax housing over the drive shaft and prepared to rfit the tri-ax. I had previously marked up the tri-ax so I knew which shaft it matched to. And (for what it's worth) I'd even marked the shaft so that I could align the triax back to the same splines as before. I've since been told that the tri-ax can simply be hammered back over the end of the shaft using a suuitable drfit and brute strength. Possibly so, but I had found mine hard to remove and expected them to be a tight fit going back on. The advice I had been given, was to heat them slightly to cause them to expand a little.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">With the shaft, gaiters and housing standing vertical on my bench, I suspended the tri-ax above it. The tri-ax parts seems to have a different profile on each side and I wasn't sure whether this would aid or hamper the fitting of the circlips that secure them. Studying old photos from when i removed them, I suspended the tri-ax the same way round - just so I could be confident the circlic would go back on.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQfh1bNM5-cUf4yR4zYmWXX942ftME8RdVhMP5FC7NXwJNNcZSvr39HMqtvpNj0udmwtG9U1PSSYv4wD9A4K7Sbtyuy1754rb2z2VXVcSMBWgCVFtdqUUvl37VAnHt40h0Jtbsx1P-bx9dWm7l8ZtHlrS8TaxDXXRfWiRO9fsZHm7VrlTKSNeWVk2-/s4032/IMG_7015.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQfh1bNM5-cUf4yR4zYmWXX942ftME8RdVhMP5FC7NXwJNNcZSvr39HMqtvpNj0udmwtG9U1PSSYv4wD9A4K7Sbtyuy1754rb2z2VXVcSMBWgCVFtdqUUvl37VAnHt40h0Jtbsx1P-bx9dWm7l8ZtHlrS8TaxDXXRfWiRO9fsZHm7VrlTKSNeWVk2-/w400-h300/IMG_7015.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Getting ready to heat the tri-ax</span><br /></td></tr></tbody></table>I applied a little heat just to the main body of the tri-ax and, when I thought I'd applied enough heat, quickly lowered it onto the shaft. I'd already found a suitable socket to use as a drift and it only took a gentle tap with a hammer for the tri-ax to be fitted home on the shaft.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq6dLUFKZ6m_TRX47eQwCGqPXRg80uSq2XotHHbenKcka5hMuV7WMwfFNjEnPOk-q9sKd3-QZ4if0vI32_Zc8B16eqjwUuKQB9ZOUI2EXJY0lkpjQ75Lo26MO4hKMQPqAzuiZeyc3_zU-E6Uo7OAa3El1n19Aj2MMiLTshdCQPOJ1tTLpYIqai0cFg/s4032/IMG_7016.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq6dLUFKZ6m_TRX47eQwCGqPXRg80uSq2XotHHbenKcka5hMuV7WMwfFNjEnPOk-q9sKd3-QZ4if0vI32_Zc8B16eqjwUuKQB9ZOUI2EXJY0lkpjQ75Lo26MO4hKMQPqAzuiZeyc3_zU-E6Uo7OAa3El1n19Aj2MMiLTshdCQPOJ1tTLpYIqai0cFg/w300-h400/IMG_7016.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">'Landing' the tri-ax on the shaft</span><br /></td></tr></tbody></table>You know it's fitted when you can clearly see the groove where the circlip will need to fit.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOI9AcZu05dibPL5FKB5Vg3NUsvUF37a_gL407SxxaMwcktAfob2d9UlzhuS0oMy4SUAkbQfi5VDGahzU6A-Vahby0zqQzQ6u8hGSV_UO0oc67JNWxgZpCjqlGBkF1IvZOm4cFmDutGkt93nx2DX_lHMBOi9OXBSnWpj7cmLYRm-alL2epgozKv4Da/s4032/IMG_7018.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOI9AcZu05dibPL5FKB5Vg3NUsvUF37a_gL407SxxaMwcktAfob2d9UlzhuS0oMy4SUAkbQfi5VDGahzU6A-Vahby0zqQzQ6u8hGSV_UO0oc67JNWxgZpCjqlGBkF1IvZOm4cFmDutGkt93nx2DX_lHMBOi9OXBSnWpj7cmLYRm-alL2epgozKv4Da/w400-h300/IMG_7018.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Retaining circlip fitted under the splines</span></td></tr></tbody></table></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I was surprised at how much heat was then transfered into the shaft and it was a while before I could refit the securing circlips. One cool, it was time to fit the rollers and secure the gaiters. The
alloy tri-ax housings have three steel sleeves for the rollers. A common
problem is that, as the joints wear, the sleeves develop a bit of a
groove and the joints become stiff and/ or noisy. Several
of my sleeves were starting to show wear. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEAAvvS-lXQzRvj4YTG6WJcRka9PwhV5qd19UYloqEd4mRYKvNe6bvMDoq5Oak4FXJtrR91mv6_hzVlAPFA0Bnah4IseOzQ0om0vqzxCtv9H_F596SlXCUf5YJ-BewfNe4TxiBXlDPkJO--a6xtHl72mzo-t43njK6p9xfhy7AJX1xTPz3cL7ZSiWi/s4032/IMG_6960.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEAAvvS-lXQzRvj4YTG6WJcRka9PwhV5qd19UYloqEd4mRYKvNe6bvMDoq5Oak4FXJtrR91mv6_hzVlAPFA0Bnah4IseOzQ0om0vqzxCtv9H_F596SlXCUf5YJ-BewfNe4TxiBXlDPkJO--a6xtHl72mzo-t43njK6p9xfhy7AJX1xTPz3cL7ZSiWi/w400-h300/IMG_6960.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Tri-ax sleeve - with signs of wear</span><br /></td></tr></tbody></table>A quick and easy solution is
to swap the sleeves fromthe hosuing on one side of the car, to the
housing on the other side of the car. A bit like swapping carr tyres
over to even up the wear, swapping the sleeves in this way means that
the rollers in the joints are no longer contacting the part of the sleeve
that was showing signs of wear.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I had been told not to muddle up the balls, tri-ax ends and sleeves, but now that I had swapped the sleeves around, I judged that all bets were off and just re-assembed things. I was (am!) relying on new grease helping to slow future wear. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The joints have to be generously greased. Each of the aluminium housings needs 200g of CV joint gease. With the shaft/ hub assembly still standing upright on the bench, I smeared some grease around the backs of the sleeves and fitted them in the housing. I then put about 100g of grease in the receeses where the rollers would fit. I put more grease on the roller shafts and fitted the rollers. With the housing pulled over the rollers, I redistributed the displaced grease and used up the remainder of the alloted 200g. I fitted new paper gaskets before capping off the housings. With the housings fitted to the shafts, I fitted Ligarex banding to secure the gaiters.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTGr4qCplE5zkb-QkFsFfsOX8iyz4iqD8pOHI3um2SIFxFzTMReqKTv377L0yXyeC_O8BRmoB8ZJZPOnkTVCkjIxln5QJFCUWwJoRlqq6iKdVLtIx7eQm9s00gDgHmt4KderQUjkyNkWE-wZRShhKv5bydqL8Nyx3tmaqH9ysrJHHhfv7ks8f4gmlv/s4032/IMG_7021.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTGr4qCplE5zkb-QkFsFfsOX8iyz4iqD8pOHI3um2SIFxFzTMReqKTv377L0yXyeC_O8BRmoB8ZJZPOnkTVCkjIxln5QJFCUWwJoRlqq6iKdVLtIx7eQm9s00gDgHmt4KderQUjkyNkWE-wZRShhKv5bydqL8Nyx3tmaqH9ysrJHHhfv7ks8f4gmlv/w400-h300/IMG_7021.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">New gaiters fitted.</span><br /></td></tr></tbody></table>All ready to fit back on the car now - giving me, once again, a rolling chassis. I will need that if I'm going to get the engine back in this summer.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-22585419067058994532023-06-20T17:13:00.001+00:002024-01-02T15:27:17.920+00:00Replacing The Clutch........again......<div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">I'm actuallly pleased that I did this all over again. No, really!</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEik8ukts9TrGUlQj5yUyDknTdphAOQMEqL5ZTXjZRVlVu0f-EdiY4ZC4WI1vv9SoIOSjnL5_x3U4i4CHkbHgikdbfo-YVtJxb5luMeTiobPOji1nzBFax5wgwgGpx1Q-fKoLGBD-8n-RQscxLOdPGKy2rgG85H9uaRaO70QCYCZrl8O4_TjrfApz44n/s4032/IMG_6988.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEik8ukts9TrGUlQj5yUyDknTdphAOQMEqL5ZTXjZRVlVu0f-EdiY4ZC4WI1vv9SoIOSjnL5_x3U4i4CHkbHgikdbfo-YVtJxb5luMeTiobPOji1nzBFax5wgwgGpx1Q-fKoLGBD-8n-RQscxLOdPGKy2rgG85H9uaRaO70QCYCZrl8O4_TjrfApz44n/w400-h300/IMG_6988.JPG" width="400" /></a></div> </span></span><span style="font-family: arial;"><span style="font-size: small;">Back
in 1993 - shortly before my ownership, the car had a new Ferodo
brand clutch fitted. In 1997 - several years after I acquired the car -
that clutch was deemed to 'not be biting properly' and (at 12559 km on
the clock), a Valeo clutch was fitted. </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">Clutch
problems (and/ or a malfunctioning CRC) were the prime suspects when my
gearbox input shaft sheared way back in November 1998 and other than a short test drive, my car has not really been on
the road again since. You can read about that <a href="https://ds-restoration.blogspot.com/2018/04/welcome-part-2.html" target="_blank">HERE</a>.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVa1JzhTzdr7qNHcupM2emyU4AtEZ8A2qubcilrXRgSvygGkxIY4xbxK6MS42jFSN9JaGxnOxG4Bc2ROoRgMgRc4PWRYrtM1znVFVf3LNF-oO-0Fo5fGgUYxHoXELHcUHO4oT1X3slFNFY3kAWABcoWSZ5XnYb7DFwU5mVNAhw4nVtaW6xvrVFHG82/s1600/engine%20split%201.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1053" data-original-width="1600" height="264" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVa1JzhTzdr7qNHcupM2emyU4AtEZ8A2qubcilrXRgSvygGkxIY4xbxK6MS42jFSN9JaGxnOxG4Bc2ROoRgMgRc4PWRYrtM1znVFVf3LNF-oO-0Fo5fGgUYxHoXELHcUHO4oT1X3slFNFY3kAWABcoWSZ5XnYb7DFwU5mVNAhw4nVtaW6xvrVFHG82/w400-h264/engine%20split%201.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Clutch replacement - 1998/ 99</span><br /></td></tr></tbody></table>After reassembly in 1998, the car had a few short test drives but was never really proven to be running okay afterwards.</span></span><span style="font-family: arial;"><span style="font-size: small;"> I then laid the car up to do other bodywork, with the speedo showing 23880 km - meaning that the Valeo clutch had only done 11300 kms - about 7000 miles.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">The old clutch was removed again, as part of the engine rebuild I did back in 2018. </span></span><span style="font-family: arial;"><span style="font-size: small;">I couldn't confirm anything was wrong with it, but neither could I confirm the three finger plate and mechanism were set up properly. </span></span><span style="font-family: arial;"><span style="font-size: small;">At that time, I was trying to budget for all the work to come and so, reluctantly, just put my old clutch back together. </span></span><span style="font-family: arial;"><span style="font-size: small;">And you can read about that <a href="https://ds-restoration.blogspot.com/2018/08/engine-rebuild-part-9-fywheel-and-clutch.html" target="_blank">HERE</a>. </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrpVESXwIe4B76bdQuOECB1lRsOkoFDQhpouCmkFCCjoRd44ESqE-WAazNF9FTlPnqgMvH7ZNU_lUI0ZxG3P4wpQDtuqxohh99uA-GJPHizsOt1Qi8lL9SOiYqNx8l7S1kkDG20SQgFPmlVIncBJx5HFpgzJvBGhTjQUhZkxdq3nz2voSnMwXBuUsZ/s1600/IMG_7198.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrpVESXwIe4B76bdQuOECB1lRsOkoFDQhpouCmkFCCjoRd44ESqE-WAazNF9FTlPnqgMvH7ZNU_lUI0ZxG3P4wpQDtuqxohh99uA-GJPHizsOt1Qi8lL9SOiYqNx8l7S1kkDG20SQgFPmlVIncBJx5HFpgzJvBGhTjQUhZkxdq3nz2voSnMwXBuUsZ/w400-h300/IMG_7198.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A crude attempt to measure the clutch fingers back in 2018.<br /></span></td></tr></tbody></table></span></span><span style="font-family: arial; font-size: small;">More recently still, I have rebuilt the CRC unit and so should be able to rule out that as a possible future problem, however uncertainties over the clutch have</span><span style="font-family: arial;"><span style="font-size: small;"> continued to niggle me. So you can understand why - now that I'm close to putting the engine back in the car again - I really want to be more confident that the clutch mechanism can be ruled-out as a further cause of problems.... </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">Even
though the old 'Valeo' branded friction plate had only covered 7000 miles - and still had visible print on it - I decided to replace it this time around in addition to a
refurbished three-finger clutch mechanism. <br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5PqQg0vu8cuKXIcFCgUBOtEld8s98XSOJIHVojaMHh3GIGgEzurikH7mUlkq6GMRI6JxvLwPB7CB2sOMkFxdXavuhd1C0GIR25BKEFAv9Z6BWpncN8sAVvdXnZbcK2HwlQmLnVzYKBp414exhjvIkgvdOlTIoiiVGUBld_zhGEs6e5M9II8ROelv1/s4032/Valeo%20clutch.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5PqQg0vu8cuKXIcFCgUBOtEld8s98XSOJIHVojaMHh3GIGgEzurikH7mUlkq6GMRI6JxvLwPB7CB2sOMkFxdXavuhd1C0GIR25BKEFAv9Z6BWpncN8sAVvdXnZbcK2HwlQmLnVzYKBp414exhjvIkgvdOlTIoiiVGUBld_zhGEs6e5M9II8ROelv1/w400-h300/Valeo%20clutch.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The old 'Valeo' clutch friction plate showed little wear...</span>..<br /></td></tr></tbody></table>The mechanism is available
as a part exchange item and, as they are heavy and expensive to mail
out, I planned to collect mine from Citroen Classics at the 2023 UK D
rally in June, and needed to have my exchange clutch ready. So late May saw me once again splitting the engine and gearbox.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">A surprising number of peripheral parts had to be removed first - the camshaft pulley, the centrifugal regulator, the hydraulic pump, the alternator......</span></span><span style="font-family: arial;"><span style="font-size: small;">as well as hydraulic pipes were connects to both bell housing and engine.</span></span><span style="font-family: arial;"><span style="font-size: small;"> It felt like a real backwards step - especially as I couldn't even be sure that the clutch i was removing was faulty. I had to keep reminding myself that, in helping to rule out a problem or source of failure, there was a potential benefit to all of this. And it was a hell of a lot easier to change the clutch now - before I dropped the engine back in. <br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">With the engine on a stand, i supported the gearbox and bell housing with my engine crane - just enough to begin taking it's weight. As the bellhosuing bolts were loosened, I made sure the crane carried the weight of the gearbox. The bellhousing bolts all undid easily with one exception. There is a long bolt that, as well as holding bellhousing and engine together, also holds the top of the starter in place.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibmFfU2aFhzTudGBTBgL11h6-QCj3GcrnlmN6R-Qqg6Mh1d9xPU77sInb9m5jwrWxl7O9q7XdnJSLAz4Qs4zLvRpxz8no1SEGjm5j8MIihLvWjWYmGAfIWfNGXtwcQx6B8ycFe_3cx6s8M8g-7EmrD3ITo5za7tXJvKvqshvhHjb91NbPdaeP2zF8S/s4032/IMG_6769%20copy%202.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibmFfU2aFhzTudGBTBgL11h6-QCj3GcrnlmN6R-Qqg6Mh1d9xPU77sInb9m5jwrWxl7O9q7XdnJSLAz4Qs4zLvRpxz8no1SEGjm5j8MIihLvWjWYmGAfIWfNGXtwcQx6B8ycFe_3cx6s8M8g-7EmrD3ITo5za7tXJvKvqshvhHjb91NbPdaeP2zF8S/w400-h300/IMG_6769%20copy%202.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">This bolt is only found on bvh cars with a centrifugal regulator</span><br /></td></tr></tbody></table> As soon as I began turning that bolt it sheared with a 'ping'. It didn't even attempt to turn. Luckily - because of the way the starter and bellhousing are fitted. a short length of sheared bolt was left sticking out of the starter. The shear point was the 'air gap' between the starter and the bellhousing.<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgw5uw2M38-JnABN4528Ds2UfXeVAxCVlnVovZkvHgHzd6omF6MPXQzrlEi-GM5Y2acmguP5s68ef_aj9Iza5C-ia2vEV36_oYWhN9PwhapAlwgtLFnZs3kJ1acImvEh3KIDMIRw5XFqV61tGh1aflGOkwcMsBQoAeYaCzRhf1qt0COFq1R345M0bPp/s4032/IMG_6903.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgw5uw2M38-JnABN4528Ds2UfXeVAxCVlnVovZkvHgHzd6omF6MPXQzrlEi-GM5Y2acmguP5s68ef_aj9Iza5C-ia2vEV36_oYWhN9PwhapAlwgtLFnZs3kJ1acImvEh3KIDMIRw5XFqV61tGh1aflGOkwcMsBQoAeYaCzRhf1qt0COFq1R345M0bPp/w400-h300/IMG_6903.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Sheared bellhousing bolt in the starter motor<br /></span></td></tr></tbody></table><span style="font-size: small;">With all bolts removed I slid the bellhousing and gearbox away and removed the starter motor. </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_dr2LVsp5_FW7rJbisZs-S3YgbzUcusGp4DXSpEEDkDgzYbUNzb-46QkWg4XcY-_IqmRQobgETuaZapRT12krE_Yohyr_MNPysL9sZNLTcnbbfjJv1pwWtU8lhd3odS1qNv6JmKLFcAY3-ayxNy1sw2rV-eth3OaCjjM36nH59QKuJvFkLEGtbMhI/s4032/IMG_6945.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_dr2LVsp5_FW7rJbisZs-S3YgbzUcusGp4DXSpEEDkDgzYbUNzb-46QkWg4XcY-_IqmRQobgETuaZapRT12krE_Yohyr_MNPysL9sZNLTcnbbfjJv1pwWtU8lhd3odS1qNv6JmKLFcAY3-ayxNy1sw2rV-eth3OaCjjM36nH59QKuJvFkLEGtbMhI/w400-h300/IMG_6945.JPG" width="400" /></a></div>With some mole grips I was able to remove the broken piece of bolt.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtSZEiCu3u1pDmiWUk7akIBeL9dMa4iz3XNA6FV6u7FvXnum1zRUtkRud169mnnXvO0QYA4TRxvTWPkL0bA6XBm3MYr2637yCqebncZNSlgyaRiijn-lXpSQXd7zWKZNi5-Rg3FiZbqiSKRM2dhgdoZPEVPWW10pyNLLmqe2Fp8Ae-PfEKo5uvMSsU/s4032/IMG_6915.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtSZEiCu3u1pDmiWUk7akIBeL9dMa4iz3XNA6FV6u7FvXnum1zRUtkRud169mnnXvO0QYA4TRxvTWPkL0bA6XBm3MYr2637yCqebncZNSlgyaRiijn-lXpSQXd7zWKZNi5-Rg3FiZbqiSKRM2dhgdoZPEVPWW10pyNLLmqe2Fp8Ae-PfEKo5uvMSsU/w400-h300/IMG_6915.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Bellhousing bolts laid out in order<br /></span></td></tr></tbody></table></span><span style="font-size: small;">I would have to deal with that broken bolt in due course.<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZO0TBdIYlIV-NKpgZ-SKxuDmko3Vu-aTyRLeCys0fwnmwS80AruY_ymJ_JqIka9nzWZPY3Ix4q4hyphenhyphenICJIGTEon4V0Zs1thIh0QQY0k6GAnjKZCKF_pZjO5AfKracGm-rQo047sMAVUJNgnEo_xJiEZ2lD_MApHFo4zzS8umnX2tyH5G838zCUJRN5/s4032/IMG_6904.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZO0TBdIYlIV-NKpgZ-SKxuDmko3Vu-aTyRLeCys0fwnmwS80AruY_ymJ_JqIka9nzWZPY3Ix4q4hyphenhyphenICJIGTEon4V0Zs1thIh0QQY0k6GAnjKZCKF_pZjO5AfKracGm-rQo047sMAVUJNgnEo_xJiEZ2lD_MApHFo4zzS8umnX2tyH5G838zCUJRN5/w400-h300/IMG_6904.jpg" width="400" /></a></div><span style="font-size: small;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> With the gearbox and bellhousing out of the way the clutch mechanism was removed.<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjcX8-Nzbi1mnpGh7Z9SQUUSrANNXzMPwKmZ3cvQYqneo_cWWBXsmN8Dsraj03sHqTEp0IgxuToVECKOK9TkygfoYStIMOM_X0Ox5N2hyPBw5Dkyze6_IYTg2Gc71npZD36LUQkyrp-vWDp9By4NrMz3jYPrrj-UchwMjgUR-xV_B9fcjog8M0z0o3/s4032/IMG_6964.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjcX8-Nzbi1mnpGh7Z9SQUUSrANNXzMPwKmZ3cvQYqneo_cWWBXsmN8Dsraj03sHqTEp0IgxuToVECKOK9TkygfoYStIMOM_X0Ox5N2hyPBw5Dkyze6_IYTg2Gc71npZD36LUQkyrp-vWDp9By4NrMz3jYPrrj-UchwMjgUR-xV_B9fcjog8M0z0o3/w400-h300/IMG_6964.JPG" width="400" /></a></div>By now it was early June and time for the UK 'D rally'. I duly handed over my old clutch and picked up it's replacement, a new friction plate and various other parts I wanted to buy.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1w1m3rg_KLntVYXSX4BNprzXVecjW95Uoxn6vq5RBZ7k0NWqYHtHfIT1GlLsRnB7jWePz75IE5cy4mmzGuj2Mgu2-GwzoNDw4ZpZc-EgYHR9g-zZbs0yagp4ApxcZa5aGcbtFVfImylbUrVrYnmZiXuORFU9PDk6mzKUDdSsoSzV1I-BPNW__IQvB/s4032/IMG_6968.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1w1m3rg_KLntVYXSX4BNprzXVecjW95Uoxn6vq5RBZ7k0NWqYHtHfIT1GlLsRnB7jWePz75IE5cy4mmzGuj2Mgu2-GwzoNDw4ZpZc-EgYHR9g-zZbs0yagp4ApxcZa5aGcbtFVfImylbUrVrYnmZiXuORFU9PDk6mzKUDdSsoSzV1I-BPNW__IQvB/w400-h300/IMG_6968.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Refurbished clutch mechanism and......<br /></span></td></tr></tbody></table><span style="font-size: small;"></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><br /></span></span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVQ_W5OqQFXoTjpGtMl0Y29Urjmb6rOlcsDACqaSC21FyP7TFc304zrMK4zYSqUAN0-L_l6K-qAQkxkJdv2m8s1TxiptWpA-i6EBDKR-sCSF8MeBnmwe33MXku48hRsF7e9rwPuShyphenhyphenrpy1JGK-P0f_X-nCeszH_QbumyNyKX6x4YhLXoarHxKa_RTa/s4032/IMG_6969.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVQ_W5OqQFXoTjpGtMl0Y29Urjmb6rOlcsDACqaSC21FyP7TFc304zrMK4zYSqUAN0-L_l6K-qAQkxkJdv2m8s1TxiptWpA-i6EBDKR-sCSF8MeBnmwe33MXku48hRsF7e9rwPuShyphenhyphenrpy1JGK-P0f_X-nCeszH_QbumyNyKX6x4YhLXoarHxKa_RTa/w400-h300/IMG_6969.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">.....new friction plate</span></span><br /></td></tr></tbody></table><span style="font-family: arial;"><span style="font-size: small;">Wth the replacement clutch safely at home, I also set about replacing that sheared bolt. As
mine is a bvh car this bolt is 'shouldered' (with hex) and has an extra
bit of threading on the tip. I'd need another one for the rebuild so
set about sourcing one. There are loads of bvh cars around so that
wasn't going to be hard, was it? Wrong! Tracking a bolt down proved very
difficult. I couldn't easily find one in the UK or Europe amongst my favourite suppliers.</span></span><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgN2FOaz-UDCGYwMg3MxGUGFC3ukQ2gIkqX07TbhxlRqUFuWa5uTZN8vHw-JqrGz64sj9qpxygmgqvBb9DZrdv1cXwF_mM4mgK1Z2EADa2JQRnYnyc_IhNAifCVEGuwKNj3it79lFZhPe2vwgWkirppnFQBxamAaowIPi90Uc4TajyWh_CLhLgWOeyO/s4032/IMG_6953.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgN2FOaz-UDCGYwMg3MxGUGFC3ukQ2gIkqX07TbhxlRqUFuWa5uTZN8vHw-JqrGz64sj9qpxygmgqvBb9DZrdv1cXwF_mM4mgK1Z2EADa2JQRnYnyc_IhNAifCVEGuwKNj3it79lFZhPe2vwgWkirppnFQBxamAaowIPi90Uc4TajyWh_CLhLgWOeyO/w400-h300/IMG_6953.jpg" width="400" /></a></div>I got as far as thinking of tapping a length of hex bar to make up a new one with a length of threaded rod(!) before I was saved. In the end,
the wider Citroen community came into its own and PaulE way over in
Rhode Island in the USA kindly found one and sent it over the pond. <br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiK4QX9PeSpPpEeJdqXC0DGykoyIQmLJ3tg1iB27lPN9Q9bIGmbc2sv4U11AiGVJsf4KzhG90YBpArKtvW5R4SAdQrlyE8YY0ApFhoGad_UnbXVsotn0jcDcgUAqgoKdyghuP2aJEHISw06nApko6rJndumRMllbiAIlp9JSCzWywYazZpVJ68-vGd/s4032/IMG_7028.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiK4QX9PeSpPpEeJdqXC0DGykoyIQmLJ3tg1iB27lPN9Q9bIGmbc2sv4U11AiGVJsf4KzhG90YBpArKtvW5R4SAdQrlyE8YY0ApFhoGad_UnbXVsotn0jcDcgUAqgoKdyghuP2aJEHISw06nApko6rJndumRMllbiAIlp9JSCzWywYazZpVJ68-vGd/w400-h300/IMG_7028.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Even this 'new' bolt has rusty threads at the same point mine sheared</span><br /></td></tr></tbody></table>And,
as so often the case amongst enthusiasts, Paul wanted no payment for it
and even covered the carriage costs to the UK himself. So a big thank
you to you Paul!</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial;">I hadn't ruled out a bent clutch fork as the cause of the earlier shaft failure and clutch adjustment problems. The clutch rebuild back in 1998 left the adjuster nut alarming close to one end of it's travel and I worried that - once the car was back on the road and the bvh was set up - I would run out of adjustment as the clutch wore. I'd sourced a NOS clutch fork and, now that everything was apart again, compared it to the fork I had renoved.</span></div></div><p style="text-align: justify;"><span style="font-family: arial;"></span></p><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjq3Up6RUNy5MDDTwDBq3yr5j18Oakagju1vRw0drMDLxvAbCAFg1obnFaT4XeEoTGRbKm9BcBaeq3oZwO1cL2-QawHvsqGUdAZrkPSFX2qQnF2NQnW0uIYwbWffNuDbdyEUtGI8kEf50JNQr7JgaJ8KRY5DDaal37uwk0IKiMZYg392H369VVD6vT6/s4032/IMG_E3924.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjq3Up6RUNy5MDDTwDBq3yr5j18Oakagju1vRw0drMDLxvAbCAFg1obnFaT4XeEoTGRbKm9BcBaeq3oZwO1cL2-QawHvsqGUdAZrkPSFX2qQnF2NQnW0uIYwbWffNuDbdyEUtGI8kEf50JNQr7JgaJ8KRY5DDaal37uwk0IKiMZYg392H369VVD6vT6/w400-h300/IMG_E3924.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">NOS ('New old stock') clutch fork</span></span><br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: justify;"><span style="font-family: arial;">No visible difference. Oh well..... at least I could rule that out then. But why, if the friction plate wasn't worn, had the adjuster been at the end of it's travel? I put some thought to clutch operation and adjustment. After several brain-busting hours arrived at this conclusion. I wonder if you will agree:</span></div><p style="margin-left: 40px; text-align: justify;"><i><span style="font-family: arial;">When
the clutch is operated, the rod (inside the rubber dust cover) presses
on the adjuster on the top end of the fork. This pushes them forwards
towards the steering rack.</span></i></p><p style="text-align: justify;"><span style="font-family: arial;"></span></p><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitOUr2rXVeWG3JNdEQrBAGI0EG7t_kaTA-Ia96PurKVmCn0j2iXJA0tQxonG-xxWKObba1LzBaNncw9oMSfxFnMsv93qC_VS0sBMoTD2baW2zHiG3n0WoMaY9_2ZzqGsZy5Qm6I-RWMtVFQq_Qh9WLs71nkLcFyzHlSNOdcDqe88HtRluDoip02GJl/s717/clutch%204.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="476" data-original-width="717" height="265" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitOUr2rXVeWG3JNdEQrBAGI0EG7t_kaTA-Ia96PurKVmCn0j2iXJA0tQxonG-xxWKObba1LzBaNncw9oMSfxFnMsv93qC_VS0sBMoTD2baW2zHiG3n0WoMaY9_2ZzqGsZy5Qm6I-RWMtVFQq_Qh9WLs71nkLcFyzHlSNOdcDqe88HtRluDoip02GJl/w400-h265/clutch%204.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The adjuster with hex end is shown here as part (3)</span></td></tr></tbody></table><div style="margin-left: 40px; text-align: justify;"><i><span style="font-family: arial;">The bottom end of the fork moves back towards the engine and press on the release bearing, </span></i><i><span style="font-family: arial;">which in turn, presses on the tips of the three clutch fingers.</span></i></div><p></p><p style="margin-left: 40px; text-align: justify;"><i><span style="font-family: arial;"></span></i></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhP9IDeLQeExn_5nQRuvLVBT6gZp9H1AWGFKfIK0uVpGvCVphkZqTu15KqTgRJhV9jUz1Kerg6SdlY86-jYSWVc5l0yvKntkDLfQfMj21hoFF1v7t6sET0GZbhtBzzkrpxNVWJJQib2nUWsdFGpuRUGtHzUMoFNYSRKmkfKqgotBh8uVQwryJwEuZ6u/s839/clutch%203.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="724" data-original-width="839" height="345" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhP9IDeLQeExn_5nQRuvLVBT6gZp9H1AWGFKfIK0uVpGvCVphkZqTu15KqTgRJhV9jUz1Kerg6SdlY86-jYSWVc5l0yvKntkDLfQfMj21hoFF1v7t6sET0GZbhtBzzkrpxNVWJJQib2nUWsdFGpuRUGtHzUMoFNYSRKmkfKqgotBh8uVQwryJwEuZ6u/w400-h345/clutch%203.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">The clutch fork moves the clutch release bearing</span></span><br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><i><span style="font-family: arial;"></span></i></div><div style="margin-left: 40px; text-align: left;"><i><span style="font-family: arial;"> </span></i></div><div style="margin-left: 40px; text-align: left;"><i><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK_Bi567gXBPCTeShekwn84OoQUsc2a1JLLy1lVMUJ0r2L0Rx2z9TSuqTurWEZ4tioNi3O56tZkjjYlP_uMEgDi7UQyUN8AUvN1eaX8PiE_A47NcbagvISk9kj8u_VvttqdA4Ew-3LBojpQMj4X1NEJfXa0frJSVreizIG6EGHCKUl6HG0K76alVeK/s2048/example%20of%20clip%20on%20the%20clutch%20fork.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2048" data-original-width="1536" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK_Bi567gXBPCTeShekwn84OoQUsc2a1JLLy1lVMUJ0r2L0Rx2z9TSuqTurWEZ4tioNi3O56tZkjjYlP_uMEgDi7UQyUN8AUvN1eaX8PiE_A47NcbagvISk9kj8u_VvttqdA4Ew-3LBojpQMj4X1NEJfXa0frJSVreizIG6EGHCKUl6HG0K76alVeK/w300-h400/example%20of%20clip%20on%20the%20clutch%20fork.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Clutch fork and release bearing (photo credit Carl Kirk?)</span><br /></td></tr></tbody></table>Through a lever action, the three fingers then pull back (compress) the springs of the clutch plate - loosening it's grip on the friction plate.</span></i></div><p></p><p style="margin-left: 40px; text-align: justify;"><i><span style="font-family: arial;"></span></i></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBnXnfz-J3YiozxYs9TAR2xfBYhbkM3Qnh5jCSQSu4-uOqySMwcNW9udWpXcg-EqXnYPbHba7_QH2spycRf4xoeWKY38qUDYVJ_Lxt4xICtM2qM1mK5qe1kdNTNHJ5X4ajsJ4R2pifK5YvJm8BVaZkaMAfqlizt3AyRjdFR9P9tcuOnTx_qKgF8l-d/s1412/clutch.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1412" data-original-width="642" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBnXnfz-J3YiozxYs9TAR2xfBYhbkM3Qnh5jCSQSu4-uOqySMwcNW9udWpXcg-EqXnYPbHba7_QH2spycRf4xoeWKY38qUDYVJ_Lxt4xICtM2qM1mK5qe1kdNTNHJ5X4ajsJ4R2pifK5YvJm8BVaZkaMAfqlizt3AyRjdFR9P9tcuOnTx_qKgF8l-d/w290-h640/clutch.jpeg" width="290" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The fingers release the pressure on the friction plate</span><br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><i><span style="font-family: arial;"></span></i></div><div style="margin-left: 40px; text-align: left;"><i><span style="font-family: arial;">If the adjuster on the top of the fork is screwed all the way <b>'in'</b> (so that the hex end is up against the fork) this pushes the top of the fork more towards the steering rack and nose of the car. The bottom end of the fork pushes against the release bearing more, which moves the three clutch fingers, which compress the clutch springs - reducing the pressure on the friction plate. In other words screwing the adjuster nut in more, ncreases the (partial) disengagement and so increases likelihood of clutch slippage.</span></i></div><p></p><p style="margin-left: 40px; text-align: justify;"><span style="font-family: arial;"><i>If the adjuster on the top od the fork is screwed all the way '<b>out'</b> (so that the hex end is at it's maximum distance from the top of the clutch fork, this pulls the top end of the fork towards the engine. The bottom ends of the fork move further away from the release bearing. When the clutch is operated, the forks have further to travel to contact the release bearing and so t</i></span><span style="font-family: arial;"><i>he result is that</i></span><span style="font-family: arial;"><i> - at 'full travel' - the bearing may not fully press on the three fingers, and the fingers do not compress and loosen the clutch plate springs. As such, the clutch may not be fully disengaged and may drag.</i> </span></p><p style="margin-left: 40px; text-align: justify;"><span style="font-family: arial;"><i>Now, as a friction plate wears in thickness and becomes thinner. The clutch plate (under its spring pressure) needs to be able to 'extend' further to continue to exert the right force on the friction plate. To achieve this, the push of the bearing on the three fingers needs to be reduced. This reduction is achieved by screwing the adjuster <b>out</b>.<br /></i></span></p><p style="text-align: justify;"><span style="font-family: arial;">So from what I can work out, and with my adjuster just about fully 'in', I don't need to worry about not being able to screw the adjuster any further in as the clutch wears, because what i will need to do is <b>screw it out </b>to compensate for wear. Does that sound right??</span></p><p style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">I also found that the adjuster eyes - that fit on the end of the fork and hold the clutch return spring - were now being remanufactured.</span></span></p><p style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwqHHdvBJAq10UXMAzgpAdbHJmvJxnTCPWKPSdHH2W0WOjH-x5REXNwCBRVT2ErfyQPKU0RwN8KUyvoLIfnYlEs17lQMXNCwwDJubteidYcjlV14ppl3aUnxQVKWXqN-lonryVVLjZbDayVv2kp_5XEdhP144DU0YOjuz3EEmhp58zOV_fcNJzKn8U/s4032/adjuster%201.jpeg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwqHHdvBJAq10UXMAzgpAdbHJmvJxnTCPWKPSdHH2W0WOjH-x5REXNwCBRVT2ErfyQPKU0RwN8KUyvoLIfnYlEs17lQMXNCwwDJubteidYcjlV14ppl3aUnxQVKWXqN-lonryVVLjZbDayVv2kp_5XEdhP144DU0YOjuz3EEmhp58zOV_fcNJzKn8U/w400-h300/adjuster%201.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Clutcher adjuster eye and spring holder</span><br /></td></tr></tbody></table>I bought one as the spring had just about worn through the hole in mine and there was a strong chance that it would fail once I pressed the car back into action. </span></span></p><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAFgT5YLv_ygyWlEkBvh4vSj3STGEq0DLA9fGf9KGJNXYHSgOKugvokYSy1jIlq6TFihRO9lzmSAJFgNVzl89sO8rEzBdjH8jniVCiZsSl6yqVg5pxmzm_kiChUnjBwYZXW1YrgmfF4O2SlX6Nw_vqLkrtQ0L5Y__Xwxpjm2zPQHYRvCD_DyF5zBHy/s4032/adjuster%202.jpeg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAFgT5YLv_ygyWlEkBvh4vSj3STGEq0DLA9fGf9KGJNXYHSgOKugvokYSy1jIlq6TFihRO9lzmSAJFgNVzl89sO8rEzBdjH8jniVCiZsSl6yqVg5pxmzm_kiChUnjBwYZXW1YrgmfF4O2SlX6Nw_vqLkrtQ0L5Y__Xwxpjm2zPQHYRvCD_DyF5zBHy/w400-h300/adjuster%202.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The clutch return spring wears the hole</span><br /></td></tr></tbody></table>Being
the kind of person I am, I would also have liked to have compared the set up
on the new clutch to the old one, but of course I'd had to hand that
old one over. Placing the new clutch on a glass plate, I measured the
height of the three fingers. They were all within a gnat's whisker of
each other but that didn't really tell me much. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">One of the 'pluses' of removing the clutch again was that could properly roughen up the flywheel and clutch plate surfaces. When I refitted the clutch a few years ago had thoroughly degreased it but, as preparation, had used a wire brush on a drill to clean the surface. I suspect this had the unintended effect of polishing the surface. This time around I used a coarse wire cup on a slow angle grinder to scuff the plate....... <br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirrjHDGvfHS8Rl9AZPp4QhpWtqUKn2vqhKttBZ-OMSbSi9sE4wlSHgCUil5uGLHm0HKzNAaXS7PUhkrThjJwPJImAmgIqeQR7a4LlvJ1ClQaHIoJ43-qFr0pXEE3TfGBX7zYt589-WJgfew9rrKsUJxGsi-_xi2rst3Off18AYnN0CO82MrMFcM6y7/s4032/IMG_6967.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirrjHDGvfHS8Rl9AZPp4QhpWtqUKn2vqhKttBZ-OMSbSi9sE4wlSHgCUil5uGLHm0HKzNAaXS7PUhkrThjJwPJImAmgIqeQR7a4LlvJ1ClQaHIoJ43-qFr0pXEE3TfGBX7zYt589-WJgfew9rrKsUJxGsi-_xi2rst3Off18AYnN0CO82MrMFcM6y7/w400-h300/IMG_6967.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">I roughened and cleaned the clutch plate surface</span><br /></td></tr></tbody></table><span style="font-size: small;">......and flywheel. </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGgk2jd7jg6W0hHgKrusz5hXvMjdO4AdwcEgyuy-UpCU_ApC0FWcuH7ZRi0021lmS2mjHc8kDIIQeT5lXwJpgDzboVG_J6xFqc88yG5JJH1e2L4Mkxgp6IW_KRVYq32rdt9yzUUaDWcilg8q2brmyOCDBftD3txxXq8Q-ctfa1t2SKPBwnfavK7oRT/s4032/IMG_6966.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGgk2jd7jg6W0hHgKrusz5hXvMjdO4AdwcEgyuy-UpCU_ApC0FWcuH7ZRi0021lmS2mjHc8kDIIQeT5lXwJpgDzboVG_J6xFqc88yG5JJH1e2L4Mkxgp6IW_KRVYq32rdt9yzUUaDWcilg8q2brmyOCDBftD3txxXq8Q-ctfa1t2SKPBwnfavK7oRT/w400-h300/IMG_6966.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Flywheel surface still shows an imprint of the Valeo friction plate pattern!</span><br /></td></tr></tbody></table>Both surfaces were then thoroughly degreased.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">The Citroen workshop manual says that the original friction plates were 8mm thick. </span></span><span style="font-family: arial;"><span style="font-size: small;">There are (reportedly) some thicker 12mm friction plates on the market. Being thicker, these don't provide enough room for the clutch mechanism to engage/ disengage as intended.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1B_M8wDWF0V1WDWcgahkGyeVW_8lUdF39OHzp_5IsaWCrWLaPokZ8Y9S3rqjb0hj1q3B-ygW4YyoaLQeVZ0cvziavpXuDP-2kLs8L2ip2mb9R-pTkEh8Ps_61ZzugVbZidEorfQID0QN8WVD222Vyof-9MznTRn140FQQgljp2CTy4JkN8Nm97ePS/s960/clutch%20disc%20thickness.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="960" data-original-width="720" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1B_M8wDWF0V1WDWcgahkGyeVW_8lUdF39OHzp_5IsaWCrWLaPokZ8Y9S3rqjb0hj1q3B-ygW4YyoaLQeVZ0cvziavpXuDP-2kLs8L2ip2mb9R-pTkEh8Ps_61ZzugVbZidEorfQID0QN8WVD222Vyof-9MznTRn140FQQgljp2CTy4JkN8Nm97ePS/w300-h400/clutch%20disc%20thickness.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Thick and thin friction plates?<br />(photo credit Dago Langen I think?)</span><br /></td></tr></tbody></table>I compared the Valeo friction plate I was removing and the new unbranded plate was fitting: bth lked t be the same.....Compressing it's surfaces together, the Valeo friction plate was 8mm thick. So was the unbranded one - so that seemed okay.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">I had, once again, borrowed an old input shaft from Peter 'Badabec' Bremner to help align the hole in the friction plate to the hole in the bearing.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhovQ7QbG2llMLIGrsh-N2nazJuVavysxZcE2tI9LoS_mGBwy_nlmY7IEIF85RGvAx1a70w9kOsyzG06Qvw2H2Z0-qYbbhUJbXu_YZrtybLorahct6m9_jyUPn_mBDvXdIeVfnHZpvBqpt5JUrzGU6aWv6Nk4EgEzzCZk66fBCqprShHcdr5mKgdfZH/s4032/IMG_6970.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhovQ7QbG2llMLIGrsh-N2nazJuVavysxZcE2tI9LoS_mGBwy_nlmY7IEIF85RGvAx1a70w9kOsyzG06Qvw2H2Z0-qYbbhUJbXu_YZrtybLorahct6m9_jyUPn_mBDvXdIeVfnHZpvBqpt5JUrzGU6aWv6Nk4EgEzzCZk66fBCqprShHcdr5mKgdfZH/w400-h300/IMG_6970.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Spare input shaft through the new friction plate</span><br /></td></tr></tbody></table>If you DON'T do this, you may well find that when it comes to marrying the gearbox back to the engine - they don't line up...... </span></span><span style="font-family: arial;"><span style="font-size: small;">You
don't need to use an old input shaft for this alignment. You can use
any rod of the right diameter - and even buy special kits of parts to do
this. however as eventually you will be trying to line your gearboxes
input shaft up, you get a better result if you do the set up with an old
spare shaft. And because the splines engage with those on the friction
plate, they help to ensure the correct fit.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkprWyCkybgFx4FvC2v8VXnDUuPQbpo_-RhJ0ZUMBjzRirmZUNl4T_PNyn0Ln8HGznWDM7xRNZ2sc8dpNLqXlgFaNGdZb8OvQdS6O5pyNwC777oZeDm1qiAIeVbRvfDzQ_Kdm0jo4_tROMu2vsIGKIVn-ZGc6uMZScHgSmATOB1y_8-DBBX7f7MgTS/s4032/IMG_6971.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkprWyCkybgFx4FvC2v8VXnDUuPQbpo_-RhJ0ZUMBjzRirmZUNl4T_PNyn0Ln8HGznWDM7xRNZ2sc8dpNLqXlgFaNGdZb8OvQdS6O5pyNwC777oZeDm1qiAIeVbRvfDzQ_Kdm0jo4_tROMu2vsIGKIVn-ZGc6uMZScHgSmATOB1y_8-DBBX7f7MgTS/w400-h300/IMG_6971.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Offering up the shaft to the bearing in the flywheel</span><br /></td></tr></tbody></table>With the friction plate held in place, i fitted the shiny new clutch plate. When fully bolted down, the plate will grip the friction plate tightly in place, so before I reached that point, I gave the input shaft a bit of a waggle to centralise the friction plate - and to make sure I could easily remove the shaft. This all helps to ensure that, once the gearbox is offered up, it's input shaft will slip easily throgh the friction plate and into the bearing in the flywheel.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKGb0t2vjMYS-VLv1xsXxGsxCsTLvjNWVLtF946MuWW1J5PyjNzXIMYI3QhP1iv2XP5xn26rSz7cJJpZLIVhhV9RPiGizObO4Dh3x7CZP36iDjr7oG_XWHEgZR6y9x7FRecaRAa0xP5S69xNxL_MlQbC66h2yviRPEywfrsFPgSf3E3zfNBdTjKkP0/s4032/IMG_6972.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKGb0t2vjMYS-VLv1xsXxGsxCsTLvjNWVLtF946MuWW1J5PyjNzXIMYI3QhP1iv2XP5xn26rSz7cJJpZLIVhhV9RPiGizObO4Dh3x7CZP36iDjr7oG_XWHEgZR6y9x7FRecaRAa0xP5S69xNxL_MlQbC66h2yviRPEywfrsFPgSf3E3zfNBdTjKkP0/w400-h300/IMG_6972.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Friction plate correctly aligned with the flywheel bearing</span><br /></td></tr></tbody></table><span style="font-size: small;">It's worth noticing here that the new clutch mechanism has strange little copper clips under each of the clutch fingers. I have seen other DS clutches with similar clips but made of plastic.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQBZT9BQbZWLrw2u1TL7HgcPR9ye2mt9FH8xu3Qqg73LqVPWxmm16y-9YqyIohjPxoS7pAgYxV5jcXEQCs0sgJA0ZmvJRIcAJX0KeRq2x4r0negrof_nxgtfgiAElkeAbGS8toclCmWm4SA6H4z5U-CyZfr4iZyEp3pqjtZaKFAx8W0nJ-YF1tBFig/s4032/IMG_6973.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQBZT9BQbZWLrw2u1TL7HgcPR9ye2mt9FH8xu3Qqg73LqVPWxmm16y-9YqyIohjPxoS7pAgYxV5jcXEQCs0sgJA0ZmvJRIcAJX0KeRq2x4r0negrof_nxgtfgiAElkeAbGS8toclCmWm4SA6H4z5U-CyZfr4iZyEp3pqjtZaKFAx8W0nJ-YF1tBFig/s320/IMG_6973.JPG" width="320" /></a></div>All these clips are doing is atrifically compressing the springs of the clutch so that you can fit the bolts and screw the plate on.</span></span><span style="font-family: arial;"><span style="font-size: small;"> Sometimes it's difficult to spot that these are clips.</span></span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1IDQmwWS897MPbmOHs_aHGfl464l0YryCwMxhpQFQ3Ev-J66umWkdxDYIRwlasxbk-IXLHjJW58pNUvcnzUYpQSK2TInHbmS_LK4zSxEtsGDyEEOeM-Sr3k1YH7PL0tM4N2KXjOle85fqGYes64pvEPdNv3oAVB4pqju5I53K9GV1Zekv6fPjlxlR/s942/clips%201.jpeg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="620" data-original-width="942" height="264" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1IDQmwWS897MPbmOHs_aHGfl464l0YryCwMxhpQFQ3Ev-J66umWkdxDYIRwlasxbk-IXLHjJW58pNUvcnzUYpQSK2TInHbmS_LK4zSxEtsGDyEEOeM-Sr3k1YH7PL0tM4N2KXjOle85fqGYes64pvEPdNv3oAVB4pqju5I53K9GV1Zekv6fPjlxlR/w400-h264/clips%201.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Can you spot the clips? (photo credit: Dirk Sassens)</span><br /></td></tr></tbody></table><span style="font-family: arial;"><span style="font-size: small;">Look carefully and make sure the fingers are free to move. These clips need to be REMOVED before you shove the gearbox back on or the clutch will not operate correctly! </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8pCMVzwGyW3lCd0ZRoT4_CsNSFW12lyFnDWVlx5P9nVd_LodxbGLKVG268SunuCo3C-vROZMNuCZfSBjY-E1_TIBVXk_YBl5Saf0SsQim2NUByK7YFppLvxICeu_nuoPNZzeYsKoHYWFNeKXuxVkjJ4HDJewc-ZV0cfQkvrepBs5bSevIBXJopixd/s4032/IMG_6976.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8pCMVzwGyW3lCd0ZRoT4_CsNSFW12lyFnDWVlx5P9nVd_LodxbGLKVG268SunuCo3C-vROZMNuCZfSBjY-E1_TIBVXk_YBl5Saf0SsQim2NUByK7YFppLvxICeu_nuoPNZzeYsKoHYWFNeKXuxVkjJ4HDJewc-ZV0cfQkvrepBs5bSevIBXJopixd/w400-h300/IMG_6976.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Removing the clips from the fingers</span><br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhF91oe46sUEmzhvBsA7g6sgTqCua2ODLNgsdDtyByKqN-bHqWZj4WL4eRSCppSTIYHWsS5lgKEaOhRiZNNRJklWsxW3cJzyM9dO0h_BL7FvcJk4sNI0ykNKLiFRwN3-tmJUZVxMX8oDG39WopSr8xdHd7o6d2fiP1kvhW1Mn-k_hXv1pfE2YE4mR3h/s4032/IMG_6978.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhF91oe46sUEmzhvBsA7g6sgTqCua2ODLNgsdDtyByKqN-bHqWZj4WL4eRSCppSTIYHWsS5lgKEaOhRiZNNRJklWsxW3cJzyM9dO0h_BL7FvcJk4sNI0ykNKLiFRwN3-tmJUZVxMX8oDG39WopSr8xdHd7o6d2fiP1kvhW1Mn-k_hXv1pfE2YE4mR3h/w400-h300/IMG_6978.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">That's it: new clutch fitted</span><br /></td></tr></tbody></table></span><span style="font-family: arial;"><span style="font-size: small;">Using the bearing to centre it, </span></span><span style="font-family: arial;"><span style="font-size: small;">I replaced the camshaft dust seal inside the bellhousing. I couldn't remember if i had adequately glued it in place last time.<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjebpqu52atkQdq2S2GtctNXuUkenqo2eRoEG_JS8SDPLBPkbZdPhRLO1ZPwP3U92j81PgDb6Hh_HgXLgdp0IWcj3xmu8jyVZB5Oastp34Q3OosgI6anH4bnT5XVmbJ5sH2g41WB4Mxdel3RvXdYDSVCsYbqi7LVtP950_BxncKZImw1RFzUA6LbbuX/s3264/IMG_7514.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjebpqu52atkQdq2S2GtctNXuUkenqo2eRoEG_JS8SDPLBPkbZdPhRLO1ZPwP3U92j81PgDb6Hh_HgXLgdp0IWcj3xmu8jyVZB5Oastp34Q3OosgI6anH4bnT5XVmbJ5sH2g41WB4Mxdel3RvXdYDSVCsYbqi7LVtP950_BxncKZImw1RFzUA6LbbuX/w400-h300/IMG_7514.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Camshaft dust seal inside the bellhousing</span><br /></td></tr></tbody></table>I carefully aligned the gearbox back to the engine so that the input shaft aligned with the clutch friction plate. It's important to be aware of the camshaft as it passes through it's bearing in the bellhosuing. You want to avoid bending the camshaft. I temporarily removed my bearing to make the alignment easier.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXMwfFKy-420d-np9K0ywwMVHe4JkWCYEa2u3iJnlSsqVNJGHK_jeAATbtV7F4rn_lAX676yXI8cMNTHV-x9NvIJT85gUfx4pqYdIuvuuIV6ZZhaxvN888HMtdDeB3P2wZFV4P3RmoX2b-l2hhfr4_edCN4k7X-hn3UPxpb2SLDJR9tzzhsk_ReOpz/s4032/IMG_6985.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXMwfFKy-420d-np9K0ywwMVHe4JkWCYEa2u3iJnlSsqVNJGHK_jeAATbtV7F4rn_lAX676yXI8cMNTHV-x9NvIJT85gUfx4pqYdIuvuuIV6ZZhaxvN888HMtdDeB3P2wZFV4P3RmoX2b-l2hhfr4_edCN4k7X-hn3UPxpb2SLDJR9tzzhsk_ReOpz/w400-h300/IMG_6985.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Introducing the gearbox to the engine.....</span><br /></td></tr></tbody></table><span style="font-size: small;">Last time I did this, the gearbox pushed the engine all around the workshop. so this time i wedged the engine against a wall. Slowly and carefully the gerabox was pushed home. Compared to the last time, it was remarkably easy and went home first time.If you struggle with this, it might be because the splines on the shaft and friction plate are not aligned. Turning a drive shaft or the gearbox - using the hand crank on the end - can help alignment.<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnsoFhCOn3NFSOf9G2oTExQJc7D9UyV8IgQ5afO-KSmh2Q7MISo3SxgTtmlNeqANCh4Pqe9JoQbFX3HvT9voxfCuZQXSBzW4CuGWhIsP5I5qCNIHSfF-_21Kjfpq5L8mrrEUwhqDDQnujjU8dP2zdrO2OeT_G0vXOruHc7ysSFjTdFwZtwWA4SyZBD/s4032/IMG_6986.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnsoFhCOn3NFSOf9G2oTExQJc7D9UyV8IgQ5afO-KSmh2Q7MISo3SxgTtmlNeqANCh4Pqe9JoQbFX3HvT9voxfCuZQXSBzW4CuGWhIsP5I5qCNIHSfF-_21Kjfpq5L8mrrEUwhqDDQnujjU8dP2zdrO2OeT_G0vXOruHc7ysSFjTdFwZtwWA4SyZBD/w400-h300/IMG_6986.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Nearly there....</span><br /></td></tr></tbody></table>I refitted the camshaft bearing and then bolted the bellhousing back up. <br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8rnhE8etLk9kYR-Qt-C6nhYeVzcjWXg77TpQSLGQNAwIMzv8GrMADdRnXQBnTB-jy6eJr5cXK50Ek4NXjiuh8EKjXX0ReKzPgWavvoZF30-OkrCN0fwgNd750srYTaBHHgRn4p4uEFjkio-W_ohm5RDetmVsA1AI9DfN578VV_WKGLlgkjpdhxxCD/s4032/IMG_6988.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8rnhE8etLk9kYR-Qt-C6nhYeVzcjWXg77TpQSLGQNAwIMzv8GrMADdRnXQBnTB-jy6eJr5cXK50Ek4NXjiuh8EKjXX0ReKzPgWavvoZF30-OkrCN0fwgNd750srYTaBHHgRn4p4uEFjkio-W_ohm5RDetmVsA1AI9DfN578VV_WKGLlgkjpdhxxCD/w400-h300/IMG_6988.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Refitting the bellhousing bolts.</span><br /></td></tr></tbody></table><br /><span style="font-size: small;">Done! All I have to do now, is put all the peripherals back on again.......<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">Having said I'm pleased I did this, I just hope the 'clutch snatch' problem is fixed once and for all.<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><br /></span></span></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-5126089663553280492023-06-02T11:11:00.001+00:002023-07-16T18:50:43.549+00:00Front Brake Calipers - Strip Down and Overhaul<div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The front brake calipers are now ready to go back on the engine.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">You need to go back to manual 518 to find the instructins for rebuilding the calipers. It's operation DX.451-3. Considering the car hadn't been driven for about 15 years, removing the pistons was very straight forward. Just used a blast of compressed air and out they popped. The rubber anti-vibration 'diablos' were also easy to get off. Remember to take the metal liner tubes out of the middle first. It helps.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkVEQSKIAX-4D1qh374SgmIhuP72QEK18OeKHpeU1VI7waTaW9rWnbugVxu8lHNTALmywmzPZ8ye_5FPNyDjN8VD47tkXu3gZFxSgXP08jbjKqt3YOG3G9mfkTsllXccXLYyOg73FCbRJdsNlayIcoIG4AvWM_SjLqbqRf37WHD8xYJ_WfZv1P_Q/s3264/IMG_8095.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkVEQSKIAX-4D1qh374SgmIhuP72QEK18OeKHpeU1VI7waTaW9rWnbugVxu8lHNTALmywmzPZ8ye_5FPNyDjN8VD47tkXu3gZFxSgXP08jbjKqt3YOG3G9mfkTsllXccXLYyOg73FCbRJdsNlayIcoIG4AvWM_SjLqbqRf37WHD8xYJ_WfZv1P_Q/w400-h300/IMG_8095.JPG" width="400" /></a></div><span style="font-family: arial;">I seperated the caliper halves.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZzPUWnan_qx83jzizMZGil4y2C_VISvARthuhFxDHbGQqGSXzuVLkV72H_j6rA9CMFZ5ujSinYrkApl1sFw2bDIkdQ5voHzRQYJPFe65ZGzTV8aH7UMOIo17kvoSVukGtilq4rbgd8fTdKue-Nxc2JJFL2h7LOERkN7X5s1MeRRWPCNmKmPlNkA/s3264/IMG_8094.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZzPUWnan_qx83jzizMZGil4y2C_VISvARthuhFxDHbGQqGSXzuVLkV72H_j6rA9CMFZ5ujSinYrkApl1sFw2bDIkdQ5voHzRQYJPFe65ZGzTV8aH7UMOIo17kvoSVukGtilq4rbgd8fTdKue-Nxc2JJFL2h7LOERkN7X5s1MeRRWPCNmKmPlNkA/w400-h300/IMG_8094.JPG" width="400" /></a></div><span style="font-family: arial;"></span><span style="font-family: arial;"> <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivlZ4lfKMx_GttcP6g0DGg-SlY6RF_EaLZXOjIGPVQ9hT17Fv3sZDVRZ6CFz40Bnsi0ZyCuOZYbFl5jvpusX7hvZ6ifGv5jC-MjSw93PYJxtOgVPmm58WgcUW0ME_BwMatPJ5n4XHNdiWLQztWKzq8_l1axK_f0kNm9puRLcDaJm9BpUA9cPmN8g/s3264/IMG_8101.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivlZ4lfKMx_GttcP6g0DGg-SlY6RF_EaLZXOjIGPVQ9hT17Fv3sZDVRZ6CFz40Bnsi0ZyCuOZYbFl5jvpusX7hvZ6ifGv5jC-MjSw93PYJxtOgVPmm58WgcUW0ME_BwMatPJ5n4XHNdiWLQztWKzq8_l1axK_f0kNm9puRLcDaJm9BpUA9cPmN8g/w400-h300/IMG_8101.JPG" width="400" /></a></div>Each caliper half has a rubber seal - to provide the main seal against hydraulic fluid leakage - and a felt dust seal.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"></span></div><div style="text-align: justify;"><span style="font-size: small;"></span></div><div style="text-align: justify;"><span style="font-size: small;"></span></div><div style="text-align: justify;"><span style="font-size: small;"></span></div><div style="text-align: justify;"><span style="font-size: small;"></span></div><div style="text-align: justify;"><span style="font-size: small;"></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhotXoYsJ3_gR-oB4IRU1p6dgdARU_J51TakO3vKNt4_2RiocJYH2yvfUe52UgbQfZC_otEakRgFIwvldmBbsI5ZnCGIwTPuP-QauHrssWAXpY61nkyIJCr1SqAaXel79OIENF2OzOtBWmi3EWkINn1CVhsHicH8Tuyo0hUW-JziDxwvm4G27a0ZQ/s3264/IMG_8098.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhotXoYsJ3_gR-oB4IRU1p6dgdARU_J51TakO3vKNt4_2RiocJYH2yvfUe52UgbQfZC_otEakRgFIwvldmBbsI5ZnCGIwTPuP-QauHrssWAXpY61nkyIJCr1SqAaXel79OIENF2OzOtBWmi3EWkINn1CVhsHicH8Tuyo0hUW-JziDxwvm4G27a0ZQ/w300-h400/IMG_8098.JPG" width="300" /></a></div><span style="font-family: arial;">The old felt seals were winkled out.......</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh7VbInKI0aMiJcOnNMmnUK81JbgNHcAzjVcB9JCwoeUYYg0LgGdcfbPd0TUwgHQtS5heeLpkKzURm2wnmMuU7RXZK6KGfWtSm8k5ElP7PrfaR7SqCxYO68Tt2483QoYAMyYOfERHVFLzHdEyR7vHI_coj27k4i_yiuWmvWkezKu0OV779I6jVRg/s3264/IMG_8111.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh7VbInKI0aMiJcOnNMmnUK81JbgNHcAzjVcB9JCwoeUYYg0LgGdcfbPd0TUwgHQtS5heeLpkKzURm2wnmMuU7RXZK6KGfWtSm8k5ElP7PrfaR7SqCxYO68Tt2483QoYAMyYOfERHVFLzHdEyR7vHI_coj27k4i_yiuWmvWkezKu0OV779I6jVRg/w400-h300/IMG_8111.JPG" width="400" /></a></div><span style="font-family: arial;"></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">......as were the rubber seals.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRSzH1YyDtT-qAr_qviHwPUU4sJDWCDF3PDdBlxWNuCbv_AJlcUSfgcjEBTVk7O0HTZVJtKlFb72iMxx-B4QpO3VtlH_B_4NFp-JHoxydG2vGNkRjTwUMRo6DgpkojPwpkvq4liQBGytSZvg8QiK0tc3PEjnglOlv2_S0szdCTEsXQw3sytBLN8Q/s3264/IMG_8112.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRSzH1YyDtT-qAr_qviHwPUU4sJDWCDF3PDdBlxWNuCbv_AJlcUSfgcjEBTVk7O0HTZVJtKlFb72iMxx-B4QpO3VtlH_B_4NFp-JHoxydG2vGNkRjTwUMRo6DgpkojPwpkvq4liQBGytSZvg8QiK0tc3PEjnglOlv2_S0szdCTEsXQw3sytBLN8Q/w400-h300/IMG_8112.JPG" width="400" /></a></div><span style="font-family: arial;">Initially I gave the parts a clean in my ultrasonic cleaner.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt3vmfrPOaE_3FXXMwEwT-XINcT_EXDAYiWFCjkLJb-xFzV7lVfXGTa3-LMFa-aKS_t3X9R_V5WuIui5jKv7c4kcPnnLJHRxEilUhsyRCGMXF8DFAcfzbTKi210nKpaI6FLG-tdIU8YelodLYaDxrQJwJn03wo0CbHApC8qvIs-ZabEAMkZlli1g/s3264/IMG_8138.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt3vmfrPOaE_3FXXMwEwT-XINcT_EXDAYiWFCjkLJb-xFzV7lVfXGTa3-LMFa-aKS_t3X9R_V5WuIui5jKv7c4kcPnnLJHRxEilUhsyRCGMXF8DFAcfzbTKi210nKpaI6FLG-tdIU8YelodLYaDxrQJwJn03wo0CbHApC8qvIs-ZabEAMkZlli1g/w400-h300/IMG_8138.JPG" width="400" /></a></div><span style="font-family: arial;">I managed to get a lot of dirt off.......</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwaP5eQQCiUBkCYdl_qpl8LXO3nwYv1ADple1FNMm36C5Y-eJ-ASwCx203JPjvOMGYLHlEkmfIXBTlgXw0Zghdk3jCSwlBWpxZx6Hyyfo4DSYd7fi6e---IbkFjYTGs51cLQg_p23NL3Mr2hdaEqpC6O_3aHQ3P9Q1spHdnE4VlR2-WneMiJxSJA/s3264/IMG_8139.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwaP5eQQCiUBkCYdl_qpl8LXO3nwYv1ADple1FNMm36C5Y-eJ-ASwCx203JPjvOMGYLHlEkmfIXBTlgXw0Zghdk3jCSwlBWpxZx6Hyyfo4DSYd7fi6e---IbkFjYTGs51cLQg_p23NL3Mr2hdaEqpC6O_3aHQ3P9Q1spHdnE4VlR2-WneMiJxSJA/w400-h300/IMG_8139.JPG" width="400" /></a></div><span style="font-family: arial;">..........but ultimately wasn't happy with the results on the alloy calipers and decided to have them vapour-blasted. After I got them back, I gave them a good rinse to make sure any stray glass beads were flushed out. All of that was more than four years ago!<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Picking up the task again in 2023, I soaked new felt seals in LHM for a couple of hours before fitting and gave the rubber seals a brush with LHM before fitting those. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcxqD-G-q16WTshp7_itoDSN6CMnlyTelkD0Wh-FroPr9eqle6SWFDMJv1faIrw_e5mMmtOwgE1ly90ns4DhXK8qyUX1QPmmTv2XYqj8gPcALyZC24l0oXbB1dg8Z6TcCbk43fOwydRrlb1fWkiyBSGxoX3VORF6E7Dlwttf9s_G6aCbJQTzqlABo7/s4032/IMG_6839.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcxqD-G-q16WTshp7_itoDSN6CMnlyTelkD0Wh-FroPr9eqle6SWFDMJv1faIrw_e5mMmtOwgE1ly90ns4DhXK8qyUX1QPmmTv2XYqj8gPcALyZC24l0oXbB1dg8Z6TcCbk43fOwydRrlb1fWkiyBSGxoX3VORF6E7Dlwttf9s_G6aCbJQTzqlABo7/w400-h300/IMG_6839.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Parts organised. Felt seals soaking</span><br /></td></tr></tbody></table>They went in very easily.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgT67UXpugzAoFF04auzHZVrakxSG7NG76QD5mNFVnUqc9gVpKFu3O56M0elEEnqAuiuWrxztmGTr7mGagkjzu_Q58J3ZL2-0qLBybq00W4nmv33EU_92UFnyml1Zq_dcOdOH1Rkt8dlRADyi37OFls9Uo97bWSD8VKN4PZJ_UanKO6D8NjcXnHuA/s4032/IMG_6843.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgT67UXpugzAoFF04auzHZVrakxSG7NG76QD5mNFVnUqc9gVpKFu3O56M0elEEnqAuiuWrxztmGTr7mGagkjzu_Q58J3ZL2-0qLBybq00W4nmv33EU_92UFnyml1Zq_dcOdOH1Rkt8dlRADyi37OFls9Uo97bWSD8VKN4PZJ_UanKO6D8NjcXnHuA/w400-h300/IMG_6843.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;">New seals fitted</span><br /></td></tr></tbody></table><span style="font-family: arial;">With new seals fitted, some people have reported struggling to get the pistons to go back in the calipers but I didn't have any problems. I brushed the piston with LHM an carefully inserted it in the body - being careful to make sure that it didnt snag on the felt seal. The piston stops when it reaches the rubber seal. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">There is a very slight bevel on the lip of the piston which I think is to help it get past the rubber seal.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWeXC75JiBR9xjD7ow2nP7staA59nsS0NHVyqz_EOXk5DP8SyoNBInpWFz1Ik8Tlux3F_pjmMZ3-V1JZXxGjCa2xQsGaRskTQWzcpDavxuofpONDuyM6ER_IV7pTMy1pBWPv_OlEdkXZ10JWt20b68dXePcTbb4YfTIovpCh052mXRRROalS6xsA/s1119/bevel.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="767" data-original-width="1119" height="274" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWeXC75JiBR9xjD7ow2nP7staA59nsS0NHVyqz_EOXk5DP8SyoNBInpWFz1Ik8Tlux3F_pjmMZ3-V1JZXxGjCa2xQsGaRskTQWzcpDavxuofpONDuyM6ER_IV7pTMy1pBWPv_OlEdkXZ10JWt20b68dXePcTbb4YfTIovpCh052mXRRROalS6xsA/w400-h274/bevel.jpeg" width="400" /></a></div>I just pushed down evenly on the rim of the piston with the palm of my hands and the piston suddenly went past the seal with a 'pop'. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi27Zep80ZU2wes71UvlD6PIn3C6om_H7wPRp5UMDTOqBKGaYa76Y5Iep0v1ns9AuKqesiC7KpcZF9c3eiCgjoHA8DQuV5BhTE-uBeK5-iaxSo1mrHxTVXpCrkO1-sLRkvWUYi6J4E6SnFSJFAt1ERAUnNFgOXW1j5nyznalbr0tNSalpw-VRVNog/s4032/IMG_6851.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi27Zep80ZU2wes71UvlD6PIn3C6om_H7wPRp5UMDTOqBKGaYa76Y5Iep0v1ns9AuKqesiC7KpcZF9c3eiCgjoHA8DQuV5BhTE-uBeK5-iaxSo1mrHxTVXpCrkO1-sLRkvWUYi6J4E6SnFSJFAt1ERAUnNFgOXW1j5nyznalbr0tNSalpw-VRVNog/w400-h300/IMG_6851.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A piston refitted</span><br /></td></tr></tbody></table></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I reunited the caliper halves and torqued them up (49 Nms).<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4Eo4kQyouud1NXcxy20HsmkGSRGs3m2V7kcd6RVZ-V7PriAvajD4H3k8y4170-4GAVSP-Jlb3zKFAp7apBgPNwu-RAkyoGynHbNoLRrpHIr4qEchhY-V-OkZLkW9LzlEeRX9lbkjuVffD5CH8Wex0hGjv8tHpkQgMS7RALdi71R9phmp2dGQYNRXw/s4032/IMG_6852.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4Eo4kQyouud1NXcxy20HsmkGSRGs3m2V7kcd6RVZ-V7PriAvajD4H3k8y4170-4GAVSP-Jlb3zKFAp7apBgPNwu-RAkyoGynHbNoLRrpHIr4qEchhY-V-OkZLkW9LzlEeRX9lbkjuVffD5CH8Wex0hGjv8tHpkQgMS7RALdi71R9phmp2dGQYNRXw/w400-h300/IMG_6852.JPG" width="400" /></a></div>The rubber anti-vibration 'diablos' that are part of the front engine mount set-up had been easy to remove, but were a pain to fit. The manual says to use a little water to help ease them in but they were stubborn buggers. All four of them.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><span style="font-size: small;"><span style="font-family: arial;">My car is a
bvh so the arrangement of the hydraulic pipes is different. There are no
bleed nipples on the calipers. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjol7SjxVKI8Dg7e__AhwHUNc7XJdZMv4IxOHXnAGcT79I1lYtq1vKDmm89BIct_RoOtFkgq7C053MOyXrT_keRzNBPyVDjybmjoPbbgBfAGh8U4f6ciKCWVx4dqVo1Lp44CVPtcRM-MDX7WmA3efIU_zYpSIyU6udJ9a3OHOpL29m839GpaBGe3oxH/s1197/brake%20pipes%201%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="738" data-original-width="1197" height="246" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjol7SjxVKI8Dg7e__AhwHUNc7XJdZMv4IxOHXnAGcT79I1lYtq1vKDmm89BIct_RoOtFkgq7C053MOyXrT_keRzNBPyVDjybmjoPbbgBfAGh8U4f6ciKCWVx4dqVo1Lp44CVPtcRM-MDX7WmA3efIU_zYpSIyU6udJ9a3OHOpL29m839GpaBGe3oxH/w400-h246/brake%20pipes%201%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Working out the pipe connections</span><br /></td></tr></tbody></table>Instead
the right hand brake unit is bled from the centrifugal regulator
sitting over the hydraulic pump, and the left hand unit is bled from the
accelerated idling device connected to the carburetor!</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I
found one of the bolts and the clamps for the brake pipes.........but
then spent AGES looking for the one shouldered bolt that serves to hold a
brake pipe clamp and also some other clamp that I simply can't
remember. I'd definitely had it, as it was there in one of my
disassembly photos. <br /></span></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0ix7gevAv8QufKsIR2kv3VLOjTMRbpAk43h9g19FY0l1wHbrQDyuZmIvE4Aht-HXdW4u3ZCQjzu3VMcWI8q8s7CUBfrJCib5eFCXYx-NlaJ761WPpK23_JD5ZURM68YwsGUDAmekGjKwuMMXGbEvTdKmqpfqJYVz-nZjppH-jpiVj1bBjHJ9obQ/s3264/DX2_brake%20caliper%20pipe%20routing2.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0ix7gevAv8QufKsIR2kv3VLOjTMRbpAk43h9g19FY0l1wHbrQDyuZmIvE4Aht-HXdW4u3ZCQjzu3VMcWI8q8s7CUBfrJCib5eFCXYx-NlaJ761WPpK23_JD5ZURM68YwsGUDAmekGjKwuMMXGbEvTdKmqpfqJYVz-nZjppH-jpiVj1bBjHJ9obQ/w400-h300/DX2_brake%20caliper%20pipe%20routing2.JPG" width="400" /></a></div><span style="font-family: arial;">I'd even put it aside for zinc-plating at some point.</span></span></div><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEii27XraWt5lD6CldaeQBNrFLpaLSGXj4U6gZjS1Suqdsoo-aFn3AfoZyXJFUUDBSp0AqXCWMMZpvGH7NJ1ehMmnlRtLe--yqVejQgKzs5iTORb-eXXmpKZUtU92u9vsfXzBJUhn-uOLoRp0xtutK4VmOeYUssOaMwi5D8kAwu-zRNPRIPfG8lHdw/s3264/IMG_9374%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEii27XraWt5lD6CldaeQBNrFLpaLSGXj4U6gZjS1Suqdsoo-aFn3AfoZyXJFUUDBSp0AqXCWMMZpvGH7NJ1ehMmnlRtLe--yqVejQgKzs5iTORb-eXXmpKZUtU92u9vsfXzBJUhn-uOLoRp0xtutK4VmOeYUssOaMwi5D8kAwu-zRNPRIPfG8lHdw/w400-h300/IMG_9374%20copy.jpg" width="400" /></a></div></span><span style="font-family: arial; font-size: small;">But
couldn't find it in 'box 14'.........I looked through all my other
boxes before I found it. In Box 14 the whle time. Grrrrr! </span><span style="font-family: arial; font-size: small;"><span>With the bolt found, </span></span><span style="font-size: small;"><span style="font-family: arial;">I
refitted the hydraulic pipes that join the caliper halves. </span></span><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEganbUykOcb7jhipH3vMqG8UPciYDcKlml_AsFi2ovILHtUxbv-1eJeEwULlU2_CvocsAnfkyEVjZAe5vgNSn4ai8OB6uH4gUcyWFQ3jZX5jAGnO4Y-Hm1noGD7irlwulgZzj_EuosGQgkmkM_0fwpu8xhkJFDCmT7G_POYG18x0GafiFFSsw01WLnQ/s4032/IMG_6853.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEganbUykOcb7jhipH3vMqG8UPciYDcKlml_AsFi2ovILHtUxbv-1eJeEwULlU2_CvocsAnfkyEVjZAe5vgNSn4ai8OB6uH4gUcyWFQ3jZX5jAGnO4Y-Hm1noGD7irlwulgZzj_EuosGQgkmkM_0fwpu8xhkJFDCmT7G_POYG18x0GafiFFSsw01WLnQ/w400-h300/IMG_6853.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Refitting the hydraulic pipes</span><br /></td></tr></tbody></table> That's that for the moment. I'm not fitting the brake units to the car just yet.<br /></span></span></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-3243385282900214572023-05-04T21:11:00.030+00:002024-01-19T07:43:51.299+00:00CRC Rebuild.......again.......<div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> <span>Well. I finally (I think) dealt with the 'riddle of the seals'. And corrected a mistake.</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUAC5K_p1mEFZaNGcrlcdZxnU8R4xLvJOjDclGlr6QXlylwWYleTggKRAfMnMVOBJbE11NexoXhA0rBWJYxTKyJwzlows1wT9r5Ah1_sJ6yM1BvkZA5xd3toq44zfroCHfCfmUBK1U4tNQxRLIHjiJn_-7Zy9ACqbXM74HdSagF_c7Eob5UAUQyg/s4032/IMG_6901.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUAC5K_p1mEFZaNGcrlcdZxnU8R4xLvJOjDclGlr6QXlylwWYleTggKRAfMnMVOBJbE11NexoXhA0rBWJYxTKyJwzlows1wT9r5Ah1_sJ6yM1BvkZA5xd3toq44zfroCHfCfmUBK1U4tNQxRLIHjiJn_-7Zy9ACqbXM74HdSagF_c7Eob5UAUQyg/w400-h300/IMG_6901.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">All back together. Again..........<br /></span></td></tr></tbody></table></span><span style="font-family: arial; font-size: small;">I covered the overhaul of a Clutch Re-engagement Control (CRC) unit in a post back in September 2018. You can read about that <a href="https://ds-restoration.blogspot.com/2018/09/crc-unit-clutch-re-engaement-control.html" target="_blank">HERE</a>.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">I then discovered where the 'spare' and unused seal in the CRC rebuild kit went. You can read about that in my June 2019 'riddle of the seals' post <a href="https://ds-restoration.blogspot.com/2019/06/crc-rebuild-riddle-of-seals-solved.html" target="_blank">HERE</a>.</span></div><div style="text-align: justify;"><div><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1SrgRYPB4F_jNCYpno2KqEe2OdVCdgQp1AM2lIOOV9ffVFm_MttH6_vuyb1ujmILLb9J0yS8a5w36nY5-5lczevd2F33HiGedc5VJQ1LLaCUm5AP9wJMe47KbaiF_JJi20A8EiHM3sfdS4CVdsg3KemjrVmnTBFddZeSxK0rsnGWHIiFm--r9_g/s3264/IMG_7832.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1SrgRYPB4F_jNCYpno2KqEe2OdVCdgQp1AM2lIOOV9ffVFm_MttH6_vuyb1ujmILLb9J0yS8a5w36nY5-5lczevd2F33HiGedc5VJQ1LLaCUm5AP9wJMe47KbaiF_JJi20A8EiHM3sfdS4CVdsg3KemjrVmnTBFddZeSxK0rsnGWHIiFm--r9_g/w400-h300/IMG_7832.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The unaccounted-for seal always bugged me</span><br /></td></tr></tbody></table>To add to my CRC woes,</span><span style="font-family: arial; font-size: small;">
Timo contacted me and pointed out that in my original rebuild post, I'd seemed to have fitted one of
the spring assembiles the wrong way round! I investigated by pulling apart another
CRC unit </span><span style="font-family: arial; font-size: small;">and it looked at though Timo was right! You can read about that in my post from December 2019 <a href="http://ds-restoration.blogspot.com/2019/12/crc-rebuild-correction.html " target="_blank">HERE</a>.</span></div><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">At that point, what I hadn't done, was remove the CRC from my car to check that spring assembly and replace that seal. I wasn't looking forward to pulling it off the car again and it's taken me until now to do it.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHnJ9BIAXEYmjTQu6R85tpG0J7-2NV0h8nVKiEYai6uALXoU4fdVhAsrf8FN2WDaa3ALoUH19BVaufKcpnI15txfEO7TyuRE2QaLMtjXvgg-Yc5VrobQkLq1BIk7gxeKPHPQLE1foYje0-RVnGybrOny4RV9mZxZ8yfBjfV5xWlrMKlGD-jZbJwQ/s3264/IMG_8071.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHnJ9BIAXEYmjTQu6R85tpG0J7-2NV0h8nVKiEYai6uALXoU4fdVhAsrf8FN2WDaa3ALoUH19BVaufKcpnI15txfEO7TyuRE2QaLMtjXvgg-Yc5VrobQkLq1BIk7gxeKPHPQLE1foYje0-RVnGybrOny4RV9mZxZ8yfBjfV5xWlrMKlGD-jZbJwQ/w300-h400/IMG_8071.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The CRC fitted to the car</span><br /></td></tr></tbody></table>The two jobs I needed to do meant almost a complete disassembly of the CRC. I say 'almost' because I didn't need to remove the caps from both chambers - just the one with the incorrect spring set up - and because there is an adjuster screw that shouldn't be tampered with. This was a job of two halves. The CRC sperates in the middle. the seal replacement involved one half and the spring replacement involved the other.</span></div></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjs2MSRHx1Yb7WJAFBIPW2kuUp-F0Kd4L5Y2LEM8zKdDGgg8Ky5GOUAlSaaZcQGdhKspmmeFegwLzQlG-_gVwcwNaIXbqku2xcVl7NCUCRFNnMFwIHF6xA2zzfZYfLxRlHwOrF6mH0wc2Pg_hI4ckrzotrwJRbeWSl9a6yf4nMyYDcU3kbw9oTEyw/s3264/IMG_7815.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjs2MSRHx1Yb7WJAFBIPW2kuUp-F0Kd4L5Y2LEM8zKdDGgg8Ky5GOUAlSaaZcQGdhKspmmeFegwLzQlG-_gVwcwNaIXbqku2xcVl7NCUCRFNnMFwIHF6xA2zzfZYfLxRlHwOrF6mH0wc2Pg_hI4ckrzotrwJRbeWSl9a6yf4nMyYDcU3kbw9oTEyw/w400-h300/IMG_7815.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A game of two halves....</span><br /></td></tr></tbody></table>I tackled the spring problem first as that seemed easiste to deal with. Carefully holding the body in a vice I used a suitably sized socket on the end cap to push it in very slightly. This takes pressure off the circlip. In my original rebuild I had drilled a small 'key hole' to help press out the circlip that retained the cap. An older photo - but like this.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgXa9L0Inx-mfRHUFSt98h2K5cf4_ik6clbmTFiwZs9t3M5J60u_5GUx3BqZmMlq7lHRHcJdtXPOX1Jcd1kWMpNVE3W-ds9DalGXk18r08fFHP1v58pWN0Gmnm4LfcXLCifHgb2w5JQvMnqjPUvKLHXwMWFvL84gADEtrh_zthshZzK8UgF8U4sQ/s3264/IMG_7796.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgXa9L0Inx-mfRHUFSt98h2K5cf4_ik6clbmTFiwZs9t3M5J60u_5GUx3BqZmMlq7lHRHcJdtXPOX1Jcd1kWMpNVE3W-ds9DalGXk18r08fFHP1v58pWN0Gmnm4LfcXLCifHgb2w5JQvMnqjPUvKLHXwMWFvL84gADEtrh_zthshZzK8UgF8U4sQ/w400-h300/IMG_7796.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Removing the circlip holding an end cap</span><br /></td></tr></tbody></table> With the circlip removed, the cap was removed by VERY CAREFULLY pushing on the pin inside the unit. Sure enough, when I took out the spring and it's thrust washers, I had indeed assembled them wrongly! I think I had (wrongly) assembled the parts in this chamber like the spring in the other chamber. I should have looked more carefull at my disassembly photos all those years ago.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5LX2zHb0rjwZyPDV1QlwPLDn4nPnQN5b8wxE0Ig72MjaMdgdCtkBl88rPi7Tj7pNdaYfFqKLs47MOenynFt-jbqve-HlQ-6jbo0KQj_CnujuArzRJ116Ho3_f-N9GGxl6At-XWD1rQoMTtZydOQ7enNaMeL5bzTO350Ko7iY5bxBu8JyGxbpFZg/s4032/IMG_6801.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5LX2zHb0rjwZyPDV1QlwPLDn4nPnQN5b8wxE0Ig72MjaMdgdCtkBl88rPi7Tj7pNdaYfFqKLs47MOenynFt-jbqve-HlQ-6jbo0KQj_CnujuArzRJ116Ho3_f-N9GGxl6At-XWD1rQoMTtZydOQ7enNaMeL5bzTO350Ko7iY5bxBu8JyGxbpFZg/w400-h300/IMG_6801.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">WRONG! Not like this......<br /></span></td></tr></tbody></table></span><span style="font-family: arial; font-size: small;">Relative to the end cap, the parts should fit in this order:<br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHCqIo_Wqj6OPg_OzPpOe-tCZtwxUipEN23NRa_0h8yodY70Mju_2YPZvPc6gFokmwLhckMmDsJxklorA_s-5Cnh-YnDjgoQ9-S8RUlZur5XJPbiTsRgW_JKut8ODewpfWnucpcLDdwjKTJmoeR9QzDbM4v7CTrjhHBxmXNJpvQlaqNdnC1b5zmg/s1600/My%20second%20one%20opened%20up.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHCqIo_Wqj6OPg_OzPpOe-tCZtwxUipEN23NRa_0h8yodY70Mju_2YPZvPc6gFokmwLhckMmDsJxklorA_s-5Cnh-YnDjgoQ9-S8RUlZur5XJPbiTsRgW_JKut8ODewpfWnucpcLDdwjKTJmoeR9QzDbM4v7CTrjhHBxmXNJpvQlaqNdnC1b5zmg/w400-h300/My%20second%20one%20opened%20up.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The correct order of the parts....</span><br /></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">The order of the parts was corrected and, with a brush of LHM the parts were refitted. I used a socket and vice to push the end cap on slightly further in than it's resting place. With the circlip refitted, I carefully pushed on the end pin inside the CRC againto push the cap back against the circlip. DONE.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">Next I moved on to that hidden seal. I was curious to see how I'd get on! Don't forget that I had a spare CRC unit, so if I messed this up, I had a plan 'B' up my sleeve.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiFKIdET7uUbPAcSzunCy54aYtMLaSP4v1vVM0b8jBKuF8t7syASsF1rOdexCz_4Y3q_e8c5anhnsJfcFB-pW271zrn5OJjPwZS1rUqLQV1n68u9YagjbONNcg8-SNNrVb5NOnJpO_-iM2TV4rfG6XjwtefrmjJTIxG_79u7ylK4td5whJZ6h76A/s3264/IMG_7788.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiFKIdET7uUbPAcSzunCy54aYtMLaSP4v1vVM0b8jBKuF8t7syASsF1rOdexCz_4Y3q_e8c5anhnsJfcFB-pW271zrn5OJjPwZS1rUqLQV1n68u9YagjbONNcg8-SNNrVb5NOnJpO_-iM2TV4rfG6XjwtefrmjJTIxG_79u7ylK4td5whJZ6h76A/w400-h300/IMG_7788.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Plan A and Plan B (they ARE both the same size....)</span></td></tr></tbody></table></span><span style="font-family: arial; font-size: small;"> The CRC I had chosen to rebuild back in 2018 was one I'd bought for a few Euros at Citromobile that summer. I chose to rebuild that one as it was the tattiest of the two I had and the one that would benefit most from some tlc. It had a large amount of silicone sealent cruedly smeared all over it. At the time, I wasn't aware of the 'secret seal' and I assumed this silicone was because the gasket joing the two halves was leaking. My rebuild included a gasket replacement, so no more leaks - right? It was only when I discovered where the unused 'O' ring seal went, that I realised the silicone might be because of a leaking shaft seal - and would have been no fix for such a problem. The silicone had been smeared over a bigger area than just the gasket area. All around the shaft in fact. </span><span style="font-family: arial; font-size: small;">As such, if there was a shaft leak, then my original rebuild would still leak.....</span><span style="font-family: arial; font-size: small;">. </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0UTKqLkcQJMPGhJI40AyhcwTY0mhQz-wN7QVDtusx6QeFNxVzYu447o6A8Ne3FJxeZyOI-U9YAL5boTtkxJuqF_6h1C3ex9YsxGsKuuTS8fVfpUDXCqU6MX9ngs9ydxgzSiga2kByW4dfvRs1-9_SoYccFetYW0P3g96YZDAF9G9Hqr-XMLMN4A/s3264/IMG_7755.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0UTKqLkcQJMPGhJI40AyhcwTY0mhQz-wN7QVDtusx6QeFNxVzYu447o6A8Ne3FJxeZyOI-U9YAL5boTtkxJuqF_6h1C3ex9YsxGsKuuTS8fVfpUDXCqU6MX9ngs9ydxgzSiga2kByW4dfvRs1-9_SoYccFetYW0P3g96YZDAF9G9Hqr-XMLMN4A/w400-h300/IMG_7755.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Telltale sign? The silicone sealent strongly suggests a shaft seal leak</span><br /></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">To replace the 'O' ring seal, the shaft needs to come out - or virtually all the way out. The shaft is sealed in the CRC body at one end. This
end is capped with a metal press-fit cap. The inner circumference of the
cap also acts as a kind of bearing - supporting the shaft end. <br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">The technique I followed was to remove the cap to expose the other, hidden, end of the shaft. The shaft can then be pressed out. The shaft has a cam in the middle that fits tightly on to splines. </span><span style="font-family: arial; font-size: small;">The CRC body holds back the cam and the shaft is effectively pushed through the cam and off the body. It was 'MichaelR' who first alerted me to the whereabouts of the extra seal. He had used mole grips to pull the cap out. </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_rxyQ4063a-c87aH7cQK2J2_SDxmFmPSRUKt-Q5h2dZHvUo82mzbaRtx2XofSOfdx1k00bZlj7w85s5UdG6J4kQmnX-nAWGEO1UJFZ8eSxp1HWxD1OhfX0w34hfYhaAPqzXsinunMr2Uo9uhF4Xw37kjsbdLkkbvgIVQVui3xuTpV0hgLQRr45Q/s1182/CRC_extra%20hidden%20O%20ring%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1182" data-original-width="887" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_rxyQ4063a-c87aH7cQK2J2_SDxmFmPSRUKt-Q5h2dZHvUo82mzbaRtx2XofSOfdx1k00bZlj7w85s5UdG6J4kQmnX-nAWGEO1UJFZ8eSxp1HWxD1OhfX0w34hfYhaAPqzXsinunMr2Uo9uhF4Xw37kjsbdLkkbvgIVQVui3xuTpV0hgLQRr45Q/w300-h400/CRC_extra%20hidden%20O%20ring%20copy.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">MichaelR used grips to pull the cap off (Photo credit: MichaelR)</span><br /></td></tr></tbody></table>There is not a lot of exposed end to grip and this looked quite messy - damaging the cap. Timo refined this: he welded a threaded length to the end of the cap and then would it out simply by tightening a nut on the thread. </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNP5jFnaR7wGQVDyXqzjcKr3K9kwcJl1rdDh5b4mSRVSQuba26IYVe3OQqWjfqKo_JIV3TMZcbZ4RUxti4VcjpYCCdMFRstbTKuJZAB7twriTEwczL3phjsaZr_aTW0jccMj2MFq_fqVQET2TKjQzYQzxG7sstMPVWRdbkEoOIafMNNrbfO1HtOw/s640/CRC_Timo_1%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNP5jFnaR7wGQVDyXqzjcKr3K9kwcJl1rdDh5b4mSRVSQuba26IYVe3OQqWjfqKo_JIV3TMZcbZ4RUxti4VcjpYCCdMFRstbTKuJZAB7twriTEwczL3phjsaZr_aTW0jccMj2MFq_fqVQET2TKjQzYQzxG7sstMPVWRdbkEoOIafMNNrbfO1HtOw/w400-h300/CRC_Timo_1%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Timo used a nut to wind the cap out. (Photo credit Timo)</span><br /></td></tr></tbody></table>And that is what I did.</span><span style="font-family: arial; font-size: small;">There is some hardened 'goo' around the slotted adjuster (that should not be adjusted) and the cap. I'm assuming these are to provide a fluid-proof seal against LHM leaks. Anyway the cap end was exposed and tickeled with a grinder to provide a clean wekding surface. </span><span style="font-family: arial; font-size: small;">I didn't want to mistakenly weld the cap in place, so chose a size of threaded rod that sat comfortably on the top of the cap and allowed some room for weld - on the top, not the sides of the cap. I think I chose M6 size, or maybe M5.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">It took severeal attempts to weld a rod on. the first time I tried it, winding the nut on simply pulled the threaded rod off the cap. In the end I left the end on a countersunk screw. That provided a stable base for welding (the threaded part stood vertical) and also the thin edge of the countersunk screw head succumbed more readily to my welds and joined to the cap.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQg-A8rH2wc0CzjLd-y4m4auDVIgXhV85isR0iP7uW07We2zNdZBDsPKFD56CmRmM49I7C-tZ-KiN2wdU2zZGwWFlU373Gj4srGp58xDBAtat5dT6OZk7HIZ5V5UuLQpuCyYANGETaKt0DYTQrpoy9dXYj7hX_j_LStgJTCM54caP_PwmVqO1kyg/s4032/IMG_6803.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQg-A8rH2wc0CzjLd-y4m4auDVIgXhV85isR0iP7uW07We2zNdZBDsPKFD56CmRmM49I7C-tZ-KiN2wdU2zZGwWFlU373Gj4srGp58xDBAtat5dT6OZk7HIZ5V5UuLQpuCyYANGETaKt0DYTQrpoy9dXYj7hX_j_LStgJTCM54caP_PwmVqO1kyg/w400-h300/IMG_6803.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Threaded stud welded to the cap</span><br /></td></tr></tbody></table>The rest was very easy. I used a suitabe socket to sit over the cap and threaded rod. As Timo did, using a washer and nut I wound out the cap. <br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt6gE3pjUV8ITkr6_L5cG1t_L61ElzC-nXoG67hEJiA4AGGBO_s_2uEsXT_chxk77Ra98QaJ0hRZdMhw4Dj1bEu2vB1h1YkI86Vdk2pEm0Vb7Ffc19lNSw7rYjsZ9ZZqFmPKQ2GCP3mFyMVlcbiYTZnFTd1T1TJNFuzHz5oXBce2FoN7G79wIK0w/s4032/IMG_6808.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt6gE3pjUV8ITkr6_L5cG1t_L61ElzC-nXoG67hEJiA4AGGBO_s_2uEsXT_chxk77Ra98QaJ0hRZdMhw4Dj1bEu2vB1h1YkI86Vdk2pEm0Vb7Ffc19lNSw7rYjsZ9ZZqFmPKQ2GCP3mFyMVlcbiYTZnFTd1T1TJNFuzHz5oXBce2FoN7G79wIK0w/w400-h300/IMG_6808.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Using a nut to wind the cap out</span><br /></td></tr></tbody></table></span><span style="font-family: arial; font-size: small;">It was like pulling a cork from a wine bottle and came out very easily.</span><br /><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdHclLyypWvpRzQth-8Sfr8L6BpnzSzmEP8HEVUu0mxz3rN11vqpVUQ-jnX_u1D5wWOkopzz6ZX-x4gY6v0y1g9NwrI871W4m_6U0iZ_qrsy8LzaOhxqvc-IxVXAQpEL1wQDLbXpEQQfqAhYAoyKOXYw_8TcYg2g09LQfSwB-nCzHPNMkkT1ewZQ/s4032/IMG_6811.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdHclLyypWvpRzQth-8Sfr8L6BpnzSzmEP8HEVUu0mxz3rN11vqpVUQ-jnX_u1D5wWOkopzz6ZX-x4gY6v0y1g9NwrI871W4m_6U0iZ_qrsy8LzaOhxqvc-IxVXAQpEL1wQDLbXpEQQfqAhYAoyKOXYw_8TcYg2g09LQfSwB-nCzHPNMkkT1ewZQ/w300-h400/IMG_6811.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The cap removed - not shaft end beneath</span><br /></td></tr></tbody></table>As the CRC body is made of alloy, I wanted to provide as much support around the shaft as I could when I pushed the shaft through. I used a wooden spacer with a large diameter hole cut through........</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHmWDmPdzxyo9302OHTslh45MyA5llttcsTBnfSyt4Vyv90lEj_AT5eXaeg9G5sawfBpPHaBjhO1p7yHEQXhluCuhSPJcthj23DQZJF-A7cwH2NND_SbS0NnK1DAOOEj5JET9W7D8IMGbp94zWmTUlDZmRAhGyiquzMXDHT4pmRAs4zQpbTn2uvw/s4032/IMG_6814.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHmWDmPdzxyo9302OHTslh45MyA5llttcsTBnfSyt4Vyv90lEj_AT5eXaeg9G5sawfBpPHaBjhO1p7yHEQXhluCuhSPJcthj23DQZJF-A7cwH2NND_SbS0NnK1DAOOEj5JET9W7D8IMGbp94zWmTUlDZmRAhGyiquzMXDHT4pmRAs4zQpbTn2uvw/w400-h300/IMG_6814.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Making a wooden spacer</span><br /></td></tr></tbody></table><span style="font-family: arial; font-size: small;"></span><span style="font-family: arial; font-size: small;">......so that, when pushed out, the shaft had somewhere to go.<br /></span></div><div style="text-align: justify;"></div><div style="text-align: justify;"></div><div style="text-align: justify;"></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTavhDvFz85lRpwIBunLXRCf1PHxp_Cf3DFKSD92NpTGLelldvxXpMS_648xynv1iXhA9LkpaxQ8zlGJhyis2ckBsDcZGTJxJMG-ygSA4ZshgcXnnAna28JIEBP6NLyeRmMdUhcnUcCNr7NWK57_hPBZvuxXfU2pELhjT4p-o1bokjvoOG9_XCWw/s4032/IMG_6815.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTavhDvFz85lRpwIBunLXRCf1PHxp_Cf3DFKSD92NpTGLelldvxXpMS_648xynv1iXhA9LkpaxQ8zlGJhyis2ckBsDcZGTJxJMG-ygSA4ZshgcXnnAna28JIEBP6NLyeRmMdUhcnUcCNr7NWK57_hPBZvuxXfU2pELhjT4p-o1bokjvoOG9_XCWw/w400-h300/IMG_6815.JPG" width="400" /></a></div>Using a bolt that fitted neatly in the recess where the cap had been removed........</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3cgSc3BEDvuuNcUDA91htxrlJc2chemlU1QR1qXyN-yJYfsx9BiNL6WOVTBwqFtfcCIG3j6fC2ooW5kmwL3pZYoYxUB50dQg0DyAhnqjNh7NjBwgXu-yTUWhFiQE1xBFPHh9WYoNRifBcgxHoZZu94uyk-jTDGq8MM3Y3ilx35mVMfqKa23YVow/s4032/IMG_6818.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3cgSc3BEDvuuNcUDA91htxrlJc2chemlU1QR1qXyN-yJYfsx9BiNL6WOVTBwqFtfcCIG3j6fC2ooW5kmwL3pZYoYxUB50dQg0DyAhnqjNh7NjBwgXu-yTUWhFiQE1xBFPHh9WYoNRifBcgxHoZZu94uyk-jTDGq8MM3Y3ilx35mVMfqKa23YVow/w400-h300/IMG_6818.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">I used a bolt to press the shaft out</span><br /></td></tr></tbody></table><span style="font-family: arial; font-size: small;">........I used my vice as a press to press on the shaft and push it into the wooden block. This gave me more control than hammering on the bolt and, I reasoned, was less of a 'shock' to the body - less risk of distortion.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYtYT7VtJD-yUZOgZP31psOgVhoMgCpHGApPVWcql3nh5yLDW7nSY-TpiYy3MCChDeneTGxmufzKPSGuQhvfAFmD8zAvCAyi5D6Y7EyI715QuhpL6Us1M0Fs2z_WUa3jX6ZaMocrDCvppsd3Nax7A2B8fpE4Oyk6d1KprZLtdDysO5Ke2QxyHoOA/s4032/IMG_6820.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYtYT7VtJD-yUZOgZP31psOgVhoMgCpHGApPVWcql3nh5yLDW7nSY-TpiYy3MCChDeneTGxmufzKPSGuQhvfAFmD8zAvCAyi5D6Y7EyI715QuhpL6Us1M0Fs2z_WUa3jX6ZaMocrDCvppsd3Nax7A2B8fpE4Oyk6d1KprZLtdDysO5Ke2QxyHoOA/w400-h300/IMG_6820.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Pressing out the shaft - into the wooden block</span><br /></td></tr></tbody></table>There was that pesky 'O' ring seal!</span><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhE1Y6W0NZ7u5xympcUC5dFo4NY7CxBlC8GNdptma4JhLbP8L2VeAdOfcmc4DgVqR310RpsKLNtE_nV-pIstUwZIaIoG_AcYs2C1ui7ttyufZXlpSxPZOoZQTM-U6ovfXWLDPwVeKEvNiGjmiWgxg0o-ay_b1MUsJFIJIdauP59wzAwr7DVkOJCGg/s4032/IMG_6821.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhE1Y6W0NZ7u5xympcUC5dFo4NY7CxBlC8GNdptma4JhLbP8L2VeAdOfcmc4DgVqR310RpsKLNtE_nV-pIstUwZIaIoG_AcYs2C1ui7ttyufZXlpSxPZOoZQTM-U6ovfXWLDPwVeKEvNiGjmiWgxg0o-ay_b1MUsJFIJIdauP59wzAwr7DVkOJCGg/w300-h400/IMG_6821.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The shaft seal - exposed</span><br /></td></tr></tbody></table><br /></span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgv6OOpctimmwmr4di21_9KLQEjkjT2cAoRl_apADc-aMAFGsVyJiagVso0SpnY4Sn1-3Xl9sH223eC0YONu9BXJdt7mXKw1mWaB_dKFMVIjz8Qu0TzlnEL44KnUwszRFqgeC3HD2rH5mal8PptJsjJG3kyjoFw1Kg7ODLVt6KbUKvQSdQZFlPghA/s3024/IMG_6822.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgv6OOpctimmwmr4di21_9KLQEjkjT2cAoRl_apADc-aMAFGsVyJiagVso0SpnY4Sn1-3Xl9sH223eC0YONu9BXJdt7mXKw1mWaB_dKFMVIjz8Qu0TzlnEL44KnUwszRFqgeC3HD2rH5mal8PptJsjJG3kyjoFw1Kg7ODLVt6KbUKvQSdQZFlPghA/w400-h400/IMG_6822.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Shaft with seal - note the splines for the cam</span><br /></td></tr></tbody></table><span style="font-family: arial; font-size: small;">And there was the cam left behind.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjq2J2e4eWjtr7eo5-Hs5sdbj1zokaKJnNSNmPDEt_llhD400_5m7bdYPRczxxJW1TtzwIsXe8d8S8c9aYJDq8fP6qCWV-05bjlZARF7_KBAscga7ll2-eE5fSu9JKguQphK4pMW8ZLkkDcbiMTCLPry7C8x2TyBsFM70J8NWB7jqGejxUKbA6cCQ/s4032/IMG_6825.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjq2J2e4eWjtr7eo5-Hs5sdbj1zokaKJnNSNmPDEt_llhD400_5m7bdYPRczxxJW1TtzwIsXe8d8S8c9aYJDq8fP6qCWV-05bjlZARF7_KBAscga7ll2-eE5fSu9JKguQphK4pMW8ZLkkDcbiMTCLPry7C8x2TyBsFM70J8NWB7jqGejxUKbA6cCQ/w400-h300/IMG_6825.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">All the bits</span><br /></td></tr></tbody></table></span><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">Refitting was easy. </span><span style="font-family: arial; font-size: small;">The
unused 'O' ring seal from my old rebuild kit was brushed with LHM and
fitted to the shaft. It definitely sat more proud than the old seal. </span><span style="font-family: arial; font-size: small;">I'm so glad I changed it.</span><span style="font-family: arial; font-size: small;"> <br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">I cut the stud off the CRC end cap and tidied the cap up - ready for reassembly. It looked good as new. </span><span style="font-family: arial; font-size: small;">Next thing I did was check the face of the cam - no obvious flat spots or other wear. Nothing that would make it stick. With the help of a little more LHM the shaft was located in the body - picking up the cam along the way. </span><span style="font-family: arial; font-size: small;">I first wiggled the cam to make sure it was correctly aligned to the
splines.</span><span style="font-family: arial; font-size: small;"> </span><span style="font-family: arial; font-size: small;">At this point it is VITAL that the cam is fitted on the right way! if it's 'upside down' the CRC will not opereate (and may not even go back together). I referred to drawings and my other CRC to make sure I got this bit right!</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6ECzP14E6Ks_x9HsBAFOe7o084Fi6KNrE-EiVSkcw7Ii79_s_0DKi2na_vxifcAM4GlU_TeCRsSy-qf1Dd155nt4od2hBQy2ZbSL0mNVFBQzBEKweKpFDbgaglkCsocfNe28h3Q-Pd6Zi5Ugyv9K2lp1Dt0dnmWUMGWcGeovOV67Dyox4oTGQnQ/s947/Cutaway%20of%20the%20CRC.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="763" data-original-width="947" height="323" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6ECzP14E6Ks_x9HsBAFOe7o084Fi6KNrE-EiVSkcw7Ii79_s_0DKi2na_vxifcAM4GlU_TeCRsSy-qf1Dd155nt4od2hBQy2ZbSL0mNVFBQzBEKweKpFDbgaglkCsocfNe28h3Q-Pd6Zi5Ugyv9K2lp1Dt0dnmWUMGWcGeovOV67Dyox4oTGQnQ/w400-h323/Cutaway%20of%20the%20CRC.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A schematic of the CRC. Note the way the cam is fitted</span><br /></td></tr></tbody></table> Other than making sure the cam is the right way up, there is no correct rotational orientation of the cam on the shaft - but the position of the shaft and cam need to be set up when refitting the CRC to the car. A pin is used to 'lock' the cam in the right position. </span></div><p style="text-align: justify;"><span style="font-family: arial; font-size: small;"></span></p><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilhX-j2llPNtoIQlLGtVK9ih6oI5ouZAiHJiqzhIzJfosu5hwJQELjAXpMzBtOY-F5OPaDCKkD17Iy44Wd7KBmhmrikg7T9Ov1eaM2-W9gzuQSRiyHSY8y__QWhNHUq9yj-9WXmnU7ygzb9MH5fBYKlVxD8q84xq5-fXGeCPhVdDbep2b1_PLotg/s3024/IMG_6823.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilhX-j2llPNtoIQlLGtVK9ih6oI5ouZAiHJiqzhIzJfosu5hwJQELjAXpMzBtOY-F5OPaDCKkD17Iy44Wd7KBmhmrikg7T9Ov1eaM2-W9gzuQSRiyHSY8y__QWhNHUq9yj-9WXmnU7ygzb9MH5fBYKlVxD8q84xq5-fXGeCPhVdDbep2b1_PLotg/w400-h400/IMG_6823.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The cam. Note splines and also the 'setting' hole for setting up the CRC</span><br /></td></tr></tbody></table></span></div><span style="font-family: arial; font-size: small;">Using
my vice again, I slowly pressed the shaft into the body and through the
cam. </span><span style="font-family: arial; font-size: small;">When the cam is fully engaged on it's splines the shaft cannot be pushed further. using a vice to gently push the shaft in stopped me forcing the shaft too far.</span></div><p style="text-align: justify;"><span style="font-family: arial; font-size: small;">Using my wooden block over the exposed end of the shaft again, I located the cap over the end of the shaft hole. Wiggling the shaft so that it centred in the hollow in the cap, I used my vice to squeeze the cap and wooden block together. I mixed up some Araldite and used that to seal the end cap against fluid leaks (I think).</span></p><p style="text-align: justify;"><span style="font-family: arial; font-size: small;">I won't cover further reassembly here. That's all in my original post from September 2018.<br /></span></p><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">I part-asembled the parts and gave the CRC a few coats of paint (being careful not to get panel wipe or paint inside the lubricated parts of the CRC). </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQLW56OCVWIKMPedbWEynlpwLlFAjDNvYjeWMMZn3HklQVDn1qGwqROkowc5ylMUdQHTBtZTdutsFftul2BVZbkuw60rvR622YxRn3-irUHqhucuk48pybRT7peGo9ifcR5WyOsBycMQA5L-kGPfzJCFV4Pfp9XOPujdrEyfG-3d-8JyPqT_OMWQ/s4032/IMG_6890.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQLW56OCVWIKMPedbWEynlpwLlFAjDNvYjeWMMZn3HklQVDn1qGwqROkowc5ylMUdQHTBtZTdutsFftul2BVZbkuw60rvR622YxRn3-irUHqhucuk48pybRT7peGo9ifcR5WyOsBycMQA5L-kGPfzJCFV4Pfp9XOPujdrEyfG-3d-8JyPqT_OMWQ/w400-h300/IMG_6890.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Masking and painting......</span><br /></td></tr></tbody></table><span style="font-family: arial; font-size: small;">I think this time around I will fit the1968 flector and see what happens.</span><span style="font-family: arial; font-size: small;">These are spring-loaded two-part affairs.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjpqt4AWTeuxl1JEgs2iIGrTfqLN_SVTsC_HedzjJCZaEVdXB6LboiyvSzM8r8lq4PbgOXck5Ov0soxZBEynDDtEcSXpxqprgCGO7MBVN7RCAuRUPicUjFrtES6TN0Y_fzkPUQ_pEJUNpx1f79z1-NYN5jpvAcg0UMtaAOdbchLnXptbbRiDVJ1A/s2560/20210812_131241.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1440" data-original-width="2560" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjpqt4AWTeuxl1JEgs2iIGrTfqLN_SVTsC_HedzjJCZaEVdXB6LboiyvSzM8r8lq4PbgOXck5Ov0soxZBEynDDtEcSXpxqprgCGO7MBVN7RCAuRUPicUjFrtES6TN0Y_fzkPUQ_pEJUNpx1f79z1-NYN5jpvAcg0UMtaAOdbchLnXptbbRiDVJ1A/w400-h225/20210812_131241.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Short-lived flector design (photo credit unknown)</span><br /></td></tr></tbody></table>They seem to have only been used for a couple of years (early 1966 to early 1968) before Citroen reverted to the earlier one-piece 'cartwheel' version. Perhaps I will find out why!<br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiK0lXJOMvvO6h9wcp9WJZJNlyNhDFiF7UYmYqhAnrBOcoX03ToFR2GhFDWvWEhM-q1aYwvaWQLjoq38tQsOiBhpjHJC7JialsRxjtJUb_RLFx8lX5kA1ySMH7APWp5JnBQCzgGTKxfV2kaefdPvqURMDTnS_4eFy3-_U16Rf7piWI-eKq--owhZw/s3264/IMG_7980.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiK0lXJOMvvO6h9wcp9WJZJNlyNhDFiF7UYmYqhAnrBOcoX03ToFR2GhFDWvWEhM-q1aYwvaWQLjoq38tQsOiBhpjHJC7JialsRxjtJUb_RLFx8lX5kA1ySMH7APWp5JnBQCzgGTKxfV2kaefdPvqURMDTnS_4eFy3-_U16Rf7piWI-eKq--owhZw/w400-h300/IMG_7980.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Earlier (and then also later) style of flector<br /></td></tr></tbody></table> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">Drawing to a close, something
I want to point out here is that, before and after my initial rebuild,
the shaft turned very easily against the spring tension. In fact in one
of my posts, I'd shared video from Youtube of someone with a 'knotty'
shaft - a shaft that got stuck and didn't spring back easily: this video <a href="https://www.youtube.com/watch?v=6FOjgcfSuuQ " target="_blank">HERE</a>. I had attributed this to a worn spot on the cam and the thinking being that 'loose' = 'correct'.</span></div><p style="text-align: justify;"><span style="font-family: arial; font-size: small;">N</span><span style="font-family: arial; font-size: small;">ow that I've come to change that seal, I find that the shaft is fairly tight and can barely be rotated by hand - It is able to resist the spring tension. In conclusion I can see that a shaft that rotates freely and DOEs spring back, or a shaft that does what the one in the video does, is not 'knotty' but a shaft with a worn seal - and at risk of leaking at some future point.</span></p><p style="text-align: justify;"><span style="font-family: arial; font-size: small;">I'm confident that, when fitted, and when taken alongside the springs inside the CRC, the combination of the springs on the throttle linkage, plus those on the carburetor will be enough to cause the CRC shaft to rotate as it needs to.<br /></span></p><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">One final thought. On
Facebook someone told me that you don't have to do any of the above!
All that stuff with welding and caps. They said that by pulling on the shaft end, this exposes the seal which
can be winkled out. I have to say this is one of the first things iItried before I pulled tha cap off. Pulling the shaft only exposed a dark
ring. That may have been the edge of the seal groove but, if so, gave
no scope to replace seal. In fact I think all I was seeing was a ring of
dirt and the seal remained deep inside and out of sight.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiddhWCyZ5NQFfYektjtfZedyzNp4hv5K6ag5u3S1fvnBJAQfs2OLucqzLUliqrbEBiZnr8TnLzMqo7xWmwJuEwo_66dMTHBRRnlvQsJDmurGWzoxiTXTksEVEw9iwuzQWJIj2aZ0ydi0g-zHsCdv6kdMiT2UvxH2tE8cqPxXWpLzZnEVvhfWakJQ/s4032/IMG_6838.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiddhWCyZ5NQFfYektjtfZedyzNp4hv5K6ag5u3S1fvnBJAQfs2OLucqzLUliqrbEBiZnr8TnLzMqo7xWmwJuEwo_66dMTHBRRnlvQsJDmurGWzoxiTXTksEVEw9iwuzQWJIj2aZ0ydi0g-zHsCdv6kdMiT2UvxH2tE8cqPxXWpLzZnEVvhfWakJQ/w400-h300/IMG_6838.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Gently pulling on the shaft didn't expose the 'O' ring seal....</span><br /></td></tr></tbody></table>If you could
expose the seal simply by pulling on the shaft, wouldn't this mean that
the seal could leak? From
what I can see, the only way to expose the seal without removing the
cap, would me applying significant pulling force to the shaft so that it
pulled it free of the cam inside. And that is what Manfred Wolf did: he gripped the shaft and used two screwdrivers to lever against the body.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEarwJI8f-FBeBeLQB1s2bMdzaawaISt65BetvBi8m1-toG_zLhems6koIigjXFb8eikPKgaajNJXQEFkyfzN9-Y69Qd28CS1r21kOSAX6wIkSD6VAP9tuxG8A7Oph_Z8-qr8SOC60r3MrwdWJVX-hK9EAZIixNzPcCGtijrIgALAMndy_7ROjCA/s2400/348356359_717820010112952_4920833624330214537_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1800" data-original-width="2400" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEarwJI8f-FBeBeLQB1s2bMdzaawaISt65BetvBi8m1-toG_zLhems6koIigjXFb8eikPKgaajNJXQEFkyfzN9-Y69Qd28CS1r21kOSAX6wIkSD6VAP9tuxG8A7Oph_Z8-qr8SOC60r3MrwdWJVX-hK9EAZIixNzPcCGtijrIgALAMndy_7ROjCA/w400-h300/348356359_717820010112952_4920833624330214537_n.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Levering the body (photo credit: Manfred Wolf)</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">That seemed to be enough to expose the seal.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu7LfZr-wENpegpR_ebnPIh4nH4k4lg0jgpXqfed4I6Wqs8sQzwacsMNUkLG-BOBr7by__rtaWAk2uJymxG7GhgAcdGnMWVKBp4WWaJ405TZrnLzg6xqjDdHIgTraf3ZUvYIUD0PpQzaawqcxaMW8Z1psnNdTpBGn14ARSsYxqNtJui74oUS6wBg/s2400/348356874_1619046198561486_4203285955166138736_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1800" data-original-width="2400" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu7LfZr-wENpegpR_ebnPIh4nH4k4lg0jgpXqfed4I6Wqs8sQzwacsMNUkLG-BOBr7by__rtaWAk2uJymxG7GhgAcdGnMWVKBp4WWaJ405TZrnLzg6xqjDdHIgTraf3ZUvYIUD0PpQzaawqcxaMW8Z1psnNdTpBGn14ARSsYxqNtJui74oUS6wBg/w400-h300/348356874_1619046198561486_4203285955166138736_n.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">And there is that seal again (photo credit: Manfred Wolf)</span><br /></td></tr></tbody></table>The levering technique is basically the same as the
pushing technique - where you push the shaft through the cam. Pushing
involves removing the cap as above, pulling leaves you with a gnarled
shaft I would think. Pushing is more involved but less destructive and (I feel) the
more conventional/ expected route.</span></div><div style="text-align: left;"><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I
suppose you could weld a threaded length to the exposed end of the shaft and
wind it out by tightening a nut. I'll save that thought for my
next rebuild!</span></div><br /></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-24569896356435322022023-05-01T21:15:00.002+00:002023-05-24T20:32:25.661+00:00Front Suspension Cylinders - Strip Down and Overhaul<div style="text-align: justify;"><span style="font-family: arial; font-size: small;">I have rebuilt and refitted the front suspension cylinders. The suspension arms and anti-roll bar went back on the car some time ago. I'm not sure why, but I'd moved on to refitting pipework before I put the suspension cylinders back on. All fitted now.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3uVPgQz9hu_3JHvphbecVRxuU6_PXcil3IpK844uelpGlbltFTmhqFt6gG6twJMgTJ3Czf51vOK-ZpFVjAzwKklZdhlroAtXF8pTqLQyiKvAx5O_ijMUZkJYASRG9jnHMPC003OaN7NYvKkoOLoFrIGEoj5JcgKpMtA_69becbreV5_ZCPiDG3Q/s4032/shot.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3uVPgQz9hu_3JHvphbecVRxuU6_PXcil3IpK844uelpGlbltFTmhqFt6gG6twJMgTJ3Czf51vOK-ZpFVjAzwKklZdhlroAtXF8pTqLQyiKvAx5O_ijMUZkJYASRG9jnHMPC003OaN7NYvKkoOLoFrIGEoj5JcgKpMtA_69becbreV5_ZCPiDG3Q/w400-h300/shot.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Front suspension cylinder refitted<br /></span></td></tr></tbody></table></span><span style="font-family: arial; font-size: small;">Many years ago I'd noticed that the car had an obvious LHM leak coming from somwehere around the left side wheel arch.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmrkYeW4W_GlRBdh3D-ZCHhX7MpQRz7-cSD-rIXpHc4ahxEiTEv4VgR2462H3r1tZu_WqiYhtq4F2HPGi96vGaMXZJJ3oMp3GhujUsq0YyBT7PKdx8f8BVAUwuVekX78PS9INpwEIiAapAQ7VYlLXW8VpBWeu-tD61IAMsliQrIHE_DhHAf55JNg/s3264/IMG_0665.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmrkYeW4W_GlRBdh3D-ZCHhX7MpQRz7-cSD-rIXpHc4ahxEiTEv4VgR2462H3r1tZu_WqiYhtq4F2HPGi96vGaMXZJJ3oMp3GhujUsq0YyBT7PKdx8f8BVAUwuVekX78PS9INpwEIiAapAQ7VYlLXW8VpBWeu-tD61IAMsliQrIHE_DhHAf55JNg/w300-h400/IMG_0665.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Tell tale signs of leaking LHM</span><br /></td></tr></tbody></table>I soon realised that the cause was a split boot. Pulling the car apart ore recently I'd found the other boot not leaking but badly craked. Both boots would need changing. I bought a couple of Suspension cyliner rebuild kits from Citroen Classics a few years ago and now was the time to use them. The kits were a mixture of modern-sourced parts - plus a couple of old Citroen parts - the large 'O' ring seals in the caps.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfdFB2_x_UY2wGkWLKN2jj89YDMH66x3Wvef0TjfLJ3Va_2y90pt5X_h_bl-SZexZdkYYSgH5cp4HTLkD_oPjZ5hzc8QlUTbvAJrm47NWgHlc28SOUDRTqgUHKFGIZVHx6HRFj0_QATp2y2yONxM4qhmIkXF22UOzZZ42UcfIzSaq4GxZMd3UWXA/s4032/IMG_6713.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfdFB2_x_UY2wGkWLKN2jj89YDMH66x3Wvef0TjfLJ3Va_2y90pt5X_h_bl-SZexZdkYYSgH5cp4HTLkD_oPjZ5hzc8QlUTbvAJrm47NWgHlc28SOUDRTqgUHKFGIZVHx6HRFj0_QATp2y2yONxM4qhmIkXF22UOzZZ42UcfIzSaq4GxZMd3UWXA/w400-h300/IMG_6713.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A suspension cylinder rebuild kit</span><br /></td></tr></tbody></table>Instructions for rebuilding suspension cylinders were not included in the original manual 814. You can find some instruction in English for rebuilding rear cyliders at Operation Dx.433-3 in earlier manual 518. If you are in search of instructions for front cylinders, you can find these at Operation D.433-3 in volume 3 of French language manual 583. From manual 583, here is the detail of a later style suspension cylinder:</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEib_1iU96dNOnZBw4ft77WmD4qGU6gQBDbQQcmOWGNtoVfzJDEu21b8BbuCM6Ml8vpn29RnG5gHmVzg81iUS3SiPnZ49hQTUw_-rBow21x_aDmI3bmiSIsAWVHpg4iG5f5ewPf79HZooIT_efwRIXUUu8thcFoUYeG87t5crfTgN1oQiP5tK7cbzQ/s1165/suspension%20detail.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="775" data-original-width="1165" height="426" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEib_1iU96dNOnZBw4ft77WmD4qGU6gQBDbQQcmOWGNtoVfzJDEu21b8BbuCM6Ml8vpn29RnG5gHmVzg81iUS3SiPnZ49hQTUw_-rBow21x_aDmI3bmiSIsAWVHpg4iG5f5ewPf79HZooIT_efwRIXUUu8thcFoUYeG87t5crfTgN1oQiP5tK7cbzQ/w640-h426/suspension%20detail.jpeg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Suspension cylinder parts</span><br /></td></tr></tbody></table>In the diagram above:<br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span>Part 11 is the piston <br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span>Part 7 is the sealing nut on the end.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span>Parts 6 and 10 are the felt washer and O ring inside the nut.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span>Part 5 is a thick metal thrust washer</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span>Part 8 is the white Teflon seal inside part 9, another O ring.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">Before I started the rebuild, I'd been keeping dust and dirt out of the cylinder ends using the smart blue caps that Peter Bremner made on his 3D printer. I'll also use them again when the cylinders are refitted - but before I fit spheres. <br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">With the Ligarex clips removed from the large ends, the boots can be pulled off to reveal the pushrods and end nuts of the cylinders. The pushrods remain attached to the boots by the Ligarex clips at the other end.<br /></span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGnOH2KExBb_vNYIjMvTAjSpXHi238xK9BP6tbYfjqKcOndbCegFSApJC5I04t3AQt8LkMHGM0Kwwpzet2SsNV0Ueu0NXdrTC3wmjKtAcUydaW68Dr8fcfcrCoOclWShcTUg-lfy1cJXLvVU-tFmM3OwPiOdQY525CHvbFADvCZBAkUk7wDz8fHw/s4032/IMG_6706.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGnOH2KExBb_vNYIjMvTAjSpXHi238xK9BP6tbYfjqKcOndbCegFSApJC5I04t3AQt8LkMHGM0Kwwpzet2SsNV0Ueu0NXdrTC3wmjKtAcUydaW68Dr8fcfcrCoOclWShcTUg-lfy1cJXLvVU-tFmM3OwPiOdQY525CHvbFADvCZBAkUk7wDz8fHw/w400-h300/IMG_6706.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Pushrods and cylinder nuts revealed</span><br /></td></tr></tbody></table><span style="font-family: arial; font-size: small;">Unlike
the rear suspension units, the pushrods and ball bearings of the front
units are inside the rubber gaiters and lubricated with hydraulic fluid.
The cups, rods and pins of
the front suspension cylinders are different to those of the back and I
don't know how readily available they are. </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">The nuts that close the ends of the cylinders and hold the seals in place are screwed up pretty tightly. The technique is to carefully grip the nut in a vice and then remove the body from it by using some kind of tool around the boss on the other end (where the hydraulic pipe connects) to turn the cylinder body.</span><span style="font-family: arial; font-size: small;"> The manual recommends wooden jaw liners with a 'V' cut in each. </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4d0u86IBdBuNn0XJk1H9SPqZd_WU5BwDAKw0_cfxJ9SjBhDASBbq0KuE00VRoTO-lep2K8mfMJk4oqURYdW82Fraj4kQLIj9HcAyuwKafcFtYeM0scRCbGsZq3o3iHrFjWjcEnvDFy619bQJ1d3dBpXkb1I0ImDt4v7XizzfpGaz1P5qRjgoEyg/s1106/wooden%20vice%20jaws.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="731" data-original-width="1106" height="265" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4d0u86IBdBuNn0XJk1H9SPqZd_WU5BwDAKw0_cfxJ9SjBhDASBbq0KuE00VRoTO-lep2K8mfMJk4oqURYdW82Fraj4kQLIj9HcAyuwKafcFtYeM0scRCbGsZq3o3iHrFjWjcEnvDFy619bQJ1d3dBpXkb1I0ImDt4v7XizzfpGaz1P5qRjgoEyg/w400-h265/wooden%20vice%20jaws.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The manual recommends soft jaws in a vice</span><br /></td></tr></tbody></table>You can't grip the nut too tightly in the vice for fear of distorting it and pinching it on to the body even more tightly. And there is the risk that if that happens and you manage to get it off - it won't go back over the piston and/ or seal properly. Unfortunately, if the vice isnt tight, the nut twists with the body as you try to rotate it. </span><span style="font-family: arial; font-size: small;">A
bit of trial and error is needed to find something to line the vice
jaws so that you don't need to tighted the jaws too much but still have
enough grip on the nut. <br /></span></div><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgppWvUdIBo3P1I6kkZoXCEvvvBdEDj1R0nfmOfVLbOGEuxl5ra1nD01_hkcI83L4bjiCW8g5i1VuCsxminhPHUjvxi8V4eP-tvAOZzWDFOkgydLYpvrk9txF0Ths9q0n4AmHKQvnZ98zwozwLcNXSKhf4iLU8of8Unsj9P7kRqAAbg8qlhKK8vQg/s4032/IMG_6707.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgppWvUdIBo3P1I6kkZoXCEvvvBdEDj1R0nfmOfVLbOGEuxl5ra1nD01_hkcI83L4bjiCW8g5i1VuCsxminhPHUjvxi8V4eP-tvAOZzWDFOkgydLYpvrk9txF0Ths9q0n4AmHKQvnZ98zwozwLcNXSKhf4iLU8of8Unsj9P7kRqAAbg8qlhKK8vQg/w300-h400/IMG_6707.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Seperating the nut and cylinder</span><br /></td></tr></tbody></table></span><span style="font-family: arial; font-size: small;">I used soft aluminium jaw liners and some pieces
of rubber. I wiped the cylinder body down with panel wipe so that the
rubber gripped it without slipping. </span><span style="font-family: arial; font-size: small;">Eventually was able to loosen the nut. </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhM0228Bxe6DSncaunkjSBmiOIlhZcIIOaUihe1K7mhx9-l8jzS3f5HVtMsCa_YVNk1mk5u9ML5GNxxbnYD4Y4w28ZYuRG7WknYQIa0CcAXPx_7o9f98jg8z0zxyf8uyRfECf4UVUWofLGupClkXkCaIEa1_2QUw5dE71bJpdlf9sjbO8PCRR-oQA/s4032/IMG_6708.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhM0228Bxe6DSncaunkjSBmiOIlhZcIIOaUihe1K7mhx9-l8jzS3f5HVtMsCa_YVNk1mk5u9ML5GNxxbnYD4Y4w28ZYuRG7WknYQIa0CcAXPx_7o9f98jg8z0zxyf8uyRfECf4UVUWofLGupClkXkCaIEa1_2QUw5dE71bJpdlf9sjbO8PCRR-oQA/s320/IMG_6708.JPG" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Loosened end nut on a suspension cylinder</span><br /></td></tr></tbody></table>Inside the nut was a felt dust seal. This sat in a recessed groove.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqz_NU4_OB37rHAYTsky-HWrTTn8iPPIGJtHNFdYtq2tOnxmvX_62f_LP-Acrfer-jufWWsFbiMcNoEacfWN3NpZVK94tGUY8G9LSwoVXxGHdFqwDsFU4c0tJ-qtFSm5yyxcrZtnpTdiHBvORt5c_FHBncwzYeSWYEhEPiIpZk2eW3UPpnO4ZERQ/s4032/IMG_6714.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqz_NU4_OB37rHAYTsky-HWrTTn8iPPIGJtHNFdYtq2tOnxmvX_62f_LP-Acrfer-jufWWsFbiMcNoEacfWN3NpZVK94tGUY8G9LSwoVXxGHdFqwDsFU4c0tJ-qtFSm5yyxcrZtnpTdiHBvORt5c_FHBncwzYeSWYEhEPiIpZk2eW3UPpnO4ZERQ/w400-h300/IMG_6714.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Removing the felt seal from the nut.</span><br /></td></tr></tbody></table> There was also a rubber 'O' ring that seals the nut to body join.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIy4JdGpC4DqZrJEjZ8MA1hn8imTXjW94SP6esNzGLG33nly-YNRvT9IZzGfO9dCkbVvTxa729XC1aNxTT1Cn0KHjQjIE-FbruWQLxca4gT6AyKcYh2fvGE6hmD5YwZAptmHM06oT6L5GobCmlxbko6YRfkSFhbHRtrC3DmX2CdWBwFHOXfd8ScQ/s4032/IMG_6709.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIy4JdGpC4DqZrJEjZ8MA1hn8imTXjW94SP6esNzGLG33nly-YNRvT9IZzGfO9dCkbVvTxa729XC1aNxTT1Cn0KHjQjIE-FbruWQLxca4gT6AyKcYh2fvGE6hmD5YwZAptmHM06oT6L5GobCmlxbko6YRfkSFhbHRtrC3DmX2CdWBwFHOXfd8ScQ/w400-h300/IMG_6709.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Seals inside the cylinder nut</span><br /></td></tr></tbody></table>Beneath the nut was a thick thrust washer over the cylinder piston.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPBjwkHA-HThtigKbp3tAhRxpJuqtGbMVHHIuYKzt9LMSptwvDnNnfWhhAXz6slHQMPI71dNE-H3Unw6dVI5GefsJS27PrkX1pCgAqJtEITOB8CwDWCuI-xMNVa1G-RX1ZORMHdOpGcioE71nBdnLfZeVS4WsqcH_FuoxTNcBX331BxXjFfAZ3tw/s4032/IMG_6715.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPBjwkHA-HThtigKbp3tAhRxpJuqtGbMVHHIuYKzt9LMSptwvDnNnfWhhAXz6slHQMPI71dNE-H3Unw6dVI5GefsJS27PrkX1pCgAqJtEITOB8CwDWCuI-xMNVa1G-RX1ZORMHdOpGcioE71nBdnLfZeVS4WsqcH_FuoxTNcBX331BxXjFfAZ3tw/w400-h300/IMG_6715.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Thrust washer (on the piston)</span></td></tr></tbody></table><span style="font-family: arial; font-size: small;">The thrust washer and piston were removed. Inside the circumference of the open end of the body was a white Teflon seal - within an 'O' ring that sat in a recesed groove.</span></div></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcIxwsvrpDvs1PP8_CSeFtrkNKNV_nsdonFzI-9aJ5087mikWsW23wrt43s1no52aSn6V9wNjJoog5pFUTFkzIQ8J3T9P0UyN9XvcXvX1mhNRQnDONJcJke-KXFA7jCvBw4DrPXLMAF1sHHMoUBAC4t0wcpTYlFbOBR9xSgDxs-BjeS-bxCgT6Jg/s4032/IMG_6712.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcIxwsvrpDvs1PP8_CSeFtrkNKNV_nsdonFzI-9aJ5087mikWsW23wrt43s1no52aSn6V9wNjJoog5pFUTFkzIQ8J3T9P0UyN9XvcXvX1mhNRQnDONJcJke-KXFA7jCvBw4DrPXLMAF1sHHMoUBAC4t0wcpTYlFbOBR9xSgDxs-BjeS-bxCgT6Jg/w400-h300/IMG_6712.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">White Teflon seal and 'O' ring in the cylinder end</span><br /></td></tr></tbody></table>These provide the seal againt the massive hydraulic fluid pressures at play in the suspension system. Some leakage was always anticipated - which is why the rubber boots have a return line back to the reservoir. It was at this point that I found this.....</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggzcijB9ppJKSKO7mjHZ8AlblcQnq5po3i2t_v0hVMpMhFNp1wpJlrze9VdKnUkeWEd14vIuUwXA8BHYIBq7R3KuUA0PlU6qpnAs7FAn1-4626MSvsjcjqrbrTIryVF_90nBa6k8gGs2gTCVmRFb1ktzFVJJFIzS1yg3QDNuky6QC0gjQ13ZR5hQ/s4032/IMG_6719.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggzcijB9ppJKSKO7mjHZ8AlblcQnq5po3i2t_v0hVMpMhFNp1wpJlrze9VdKnUkeWEd14vIuUwXA8BHYIBq7R3KuUA0PlU6qpnAs7FAn1-4626MSvsjcjqrbrTIryVF_90nBa6k8gGs2gTCVmRFb1ktzFVJJFIzS1yg3QDNuky6QC0gjQ13ZR5hQ/w300-h400/IMG_6719.JPG" width="300" /></a></div><span style="font-family: arial; font-size: small;">That's a bit blurry. This is better. </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7KM_X0NB64oP296R2HrvwsSRBx0hFVEsP7PZLz3PelUwS8Wm2YcQYqLXn9iv97QGPx9Zw_1A9g9N4w7blJI-ejI5wqaocKrt30OsGSGz_G2lVqn0NILjAFY_PjlBITAqCURttXg5SOMzYXpKbsIIjmWsvqk2kE5BAybhADbnimfhCJTBBrCnoKA/s4032/IMG_6720.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7KM_X0NB64oP296R2HrvwsSRBx0hFVEsP7PZLz3PelUwS8Wm2YcQYqLXn9iv97QGPx9Zw_1A9g9N4w7blJI-ejI5wqaocKrt30OsGSGz_G2lVqn0NILjAFY_PjlBITAqCURttXg5SOMzYXpKbsIIjmWsvqk2kE5BAybhADbnimfhCJTBBrCnoKA/w300-h400/IMG_6720.JPG" width="300" /></a></div>Do you recognise it?</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5nDD-eKsbKNEJDYvgOy0dziMylPgaOOb49sS--qoUGssvIwTTU2ZjMhjQYKkoi4KZ-LZjGD_zfW6RjiC1pWzE8u3jt9mVXD7-6vLx_VYRe6CN2K4XowSMh-UBnu1_YndhqObG7YOqPa48mBIsgdgPQN3czZ1QsXfyfHxYbZ5xBA3PfswGXdDebg/s4032/IMG_6722.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5nDD-eKsbKNEJDYvgOy0dziMylPgaOOb49sS--qoUGssvIwTTU2ZjMhjQYKkoi4KZ-LZjGD_zfW6RjiC1pWzE8u3jt9mVXD7-6vLx_VYRe6CN2K4XowSMh-UBnu1_YndhqObG7YOqPa48mBIsgdgPQN3czZ1QsXfyfHxYbZ5xBA3PfswGXdDebg/w300-h400/IMG_6722.JPG" width="300" /></a></div><span style="font-family: arial; font-size: small;">It's a thin sliver of hydraulic pipe seal that has found it's way into the suspension cylinder. These get 'shaved' off the seals by the threads when the pipe flare nuts are screwed in or removed. When working on the car, if you disconnect hydraulic lines you need to remember to remove and replace old seals - but also to fish out any slivers of rubber. If you don't these can compromise the working of various slide valves and they can block pipes. In my case, this sliver would have found it's way back to the reservoir from the cylinder and been picked out by the filter. <br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">Here are the parts of my two cylinders laid out.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhht0J3v29RWlIU8zcOh_8Mr5BhAnRVicgY6Kfn1lcR2JP2upB-XMdvksfeQ3Md2zYsRcLztyl5Cnke6gP1Q7oalkjdzFwmm8wapYxS0y267yyH99u9UdU1X7jtkzpFL8UFfSlMZuRTR3Or7-9y3i-WzJkkd4aHC5D87dKgvqDvM0bhWlSLdG2DcQ/s4032/IMG_6717%201.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhht0J3v29RWlIU8zcOh_8Mr5BhAnRVicgY6Kfn1lcR2JP2upB-XMdvksfeQ3Md2zYsRcLztyl5Cnke6gP1Q7oalkjdzFwmm8wapYxS0y267yyH99u9UdU1X7jtkzpFL8UFfSlMZuRTR3Or7-9y3i-WzJkkd4aHC5D87dKgvqDvM0bhWlSLdG2DcQ/w400-h300/IMG_6717%201.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Suspension cylinder parts laid out</span><br /></td></tr></tbody></table>The instructions for the old style rear cylinders in manual 814 warn that several parts and paired and shouldnt be muddled between cylinders. I wasn't sure that was the case with the newer design front cylinders but it didn't hurt to be cautious and I put a couple of discreet marks on things to help ID them.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2GxjoR06WMZaR7GfKVR-VzJ5Y-N3pRm69Pp1hxlS5xhlhQbc_632hNjowxcxCVIqHqkOCc8gfi1BgZGv4HfSez8FKQZCItF59cNQl3jypayGD0VOFVun4AjQJaDowyWD0rYCaGgQBT2U3EyXPxKJvk7i6rCP5cjRELSTtvyk7C8sEMLn6BWVSOQ/s4032/IMG_6725%201.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2GxjoR06WMZaR7GfKVR-VzJ5Y-N3pRm69Pp1hxlS5xhlhQbc_632hNjowxcxCVIqHqkOCc8gfi1BgZGv4HfSez8FKQZCItF59cNQl3jypayGD0VOFVun4AjQJaDowyWD0rYCaGgQBT2U3EyXPxKJvk7i6rCP5cjRELSTtvyk7C8sEMLn6BWVSOQ/w300-h400/IMG_6725%201.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">I carefully marked the parts to help ID them</span><br /></td></tr></tbody></table>All the parts were cleaned in petrol and I put the pistons and bodies through my ultrasonic cleaner. I gave the piston a light polish to make the surface that little bit smoother - hoping it would reduce wear and tear on the new Teflon seal.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">I didn't bother to disassemble the push rods as I wasn't sure whether replacement pins were available. That's when I found this.... the cups and pins on the pushrod ends were different. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgm8UYET0u6zl2Cchb1RD3v3DwEJEKRO91oyjECOcve9YGZXwNk3AayG5C2WQsbpZy9mQFMeOzssegsXMwF1f0u_s6ecEla1GTVTyOt4JpOa-Dqm1kLSNTuzlUz-6AoLsB3g_B7SfNPzj4RBlAyXhRzR2B4bVRo98XguWxcvqIZ0pNz01kraK-Mg/s4032/IMG_6748.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgm8UYET0u6zl2Cchb1RD3v3DwEJEKRO91oyjECOcve9YGZXwNk3AayG5C2WQsbpZy9mQFMeOzssegsXMwF1f0u_s6ecEla1GTVTyOt4JpOa-Dqm1kLSNTuzlUz-6AoLsB3g_B7SfNPzj4RBlAyXhRzR2B4bVRo98XguWxcvqIZ0pNz01kraK-Mg/w400-h300/IMG_6748.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Different cups on the pushrod ends</span><br /></td></tr></tbody></table><span style="font-family: arial; font-size: small;">Both the cups and pins are different. For the pushrod on the left, the 'fat' pin sits in a slot and then a clip around the circumference of the cup stops it slipping out. The ends of the 'thin' pin of the other pushrod sit in two holes. </span><span style="font-family: arial; font-size: small;">The difference in pin diameter also means that the pushrods themselves are different. Overall there was about 3mm difference in overall length - partly attributable to different cups but also partly down to different length pushrods.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMCQVSjTKgXSt4v5pm4zsJMB_a3OFfKcOCbSma2Evt9qfhvijQDsbd2N1pfKeUYR8sKaSxnpASYHnimI5IYfoscVBtMVmyeM02_hau7NAT1Av9jChuUf8gF1weHH4LSYoBeFa-6Z7Ig_H27WfQi5p5RUHRc2MxGW34rAFOQXZMCEU4rT5F71L1Ew/s4032/IMG_6750.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMCQVSjTKgXSt4v5pm4zsJMB_a3OFfKcOCbSma2Evt9qfhvijQDsbd2N1pfKeUYR8sKaSxnpASYHnimI5IYfoscVBtMVmyeM02_hau7NAT1Av9jChuUf8gF1weHH4LSYoBeFa-6Z7Ig_H27WfQi5p5RUHRc2MxGW34rAFOQXZMCEU4rT5F71L1Ew/w300-h400/IMG_6750.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Two pushrods, two lengths....</span></td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td><td class="tr-caption" style="text-align: center;"><br /></td></tr></tbody></table></span></div><p></p><p><span style="font-size: small;"><span style="font-family: arial;">A bit of a trawl through the parts manuals revealed that there seems to
have been a change in parts late 1970 - for the 1971 model year cars.
The shorter rod (right hand side in my photo above) looks to be the
original 1968 pushrod from my car, whereas the other one is from a 70s
car. My receipts show that I did have a cylinder replaced back in the
day, but I can't remember why that was necesary. Anyway, different they
were!</span></span><span style="font-family: arial; font-size: small;">. </span></p><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">Refiting is the reverse of disassembly. The new felt seals need to be soaked in clean LHM for a few hours before being fitted in the nuts.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpq3Cs4crhP33Aave9FfcOKmAdMyfn1q1pmbGBFEFgVjbLhC17oEwy5_PbTiMmyyXpcP2WchyCsz4OkgOg0-QFGB5Xf9eyDOdZN30yACC-FZprjESlAiJJOuNhSHBr23iTODJ59xGdnUoktCpcWUNJN4FVJtKMHvyoUvKJ46lz-tMWwe4B29ZPJQ/s4032/IMG_6726.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpq3Cs4crhP33Aave9FfcOKmAdMyfn1q1pmbGBFEFgVjbLhC17oEwy5_PbTiMmyyXpcP2WchyCsz4OkgOg0-QFGB5Xf9eyDOdZN30yACC-FZprjESlAiJJOuNhSHBr23iTODJ59xGdnUoktCpcWUNJN4FVJtKMHvyoUvKJ46lz-tMWwe4B29ZPJQ/w400-h300/IMG_6726.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Soaking the felt seals in LHM</span><br /></td></tr></tbody></table> I fitted them in the recesses in the nuts - making sure they were not twisted and sat squarely.<br /></span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwLlhpcIk8eHAwdBkzkfmNqWmAyBTUmDyMh_yz2V0EJ6F0ZfveYTZEEHhY-nTw_Cwz503LMfriKrqq1om7DI28g8UZQtY_0POa54O38C-aEKX_dy8vwEpGpNqKEoZIzeKORJLpJOoBquGMr9GFCvUWcsyJhFOpbvCnwSv49Ly_zDARr9U5r19F5Q/s4032/IMG_6727.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwLlhpcIk8eHAwdBkzkfmNqWmAyBTUmDyMh_yz2V0EJ6F0ZfveYTZEEHhY-nTw_Cwz503LMfriKrqq1om7DI28g8UZQtY_0POa54O38C-aEKX_dy8vwEpGpNqKEoZIzeKORJLpJOoBquGMr9GFCvUWcsyJhFOpbvCnwSv49Ly_zDARr9U5r19F5Q/w400-h300/IMG_6727.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">New felt seals fitted</span><br /></td></tr></tbody></table><span style="font-size: small;"><span style="font-family: arial;">The 'O' rings were brushed with LHM and also fitted inside the nuts.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZCP7_UDtkMtZJSw5TEUFQUYtyzO_318IdXZU3XAtia-03bkDfHeeVObkQsL9eX6177tCHzEOe9hbrjKse9cpiUz5QO0psNGUBF0hyuSK88ikxFH0uVAnpfn73iL02boxbT5CvUpKpj2l9zSbIpwLbb3duHYe2skbACDEKmjPmIC17SvnIB1nKgQ/s4032/IMG_6728.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZCP7_UDtkMtZJSw5TEUFQUYtyzO_318IdXZU3XAtia-03bkDfHeeVObkQsL9eX6177tCHzEOe9hbrjKse9cpiUz5QO0psNGUBF0hyuSK88ikxFH0uVAnpfn73iL02boxbT5CvUpKpj2l9zSbIpwLbb3duHYe2skbACDEKmjPmIC17SvnIB1nKgQ/w400-h300/IMG_6728.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">'O' ring for the nut - an original spare part</span></td></tr></tbody></table></span></span><span style="font-family: arial; font-size: small;"> Rebuilding is pretty straightforward and some may not bother with the workshop manual instuctions - especially if they are in French. However there is a particular - and simple - technique for safely fitting the white Teflon seals without damaging them. </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBzXLrk0FQF5EEq_W6iLcjym4TbzoJdWH60LKbStrsRpxPbNq3w6ms7RpJctwNXQSi4mC5le--aOgll4iPor31vqEKTMCGRD8cAhQMr-lcsWzmS4M2RJZzSVWDS2A9uhRY9tf4PHGEYXwrnQw07gGsbT0VWZSJfLH4uhMhGBQodHcnUq5s3VUJFw/s4032/IMG_6730.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBzXLrk0FQF5EEq_W6iLcjym4TbzoJdWH60LKbStrsRpxPbNq3w6ms7RpJctwNXQSi4mC5le--aOgll4iPor31vqEKTMCGRD8cAhQMr-lcsWzmS4M2RJZzSVWDS2A9uhRY9tf4PHGEYXwrnQw07gGsbT0VWZSJfLH4uhMhGBQodHcnUq5s3VUJFw/w400-h300/IMG_6730.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Teflon suspension cylinder seal</span><br /></td></tr></tbody></table>I have seen elsewhere on the internet, photos of people trying to fit the Teflon seal by inserting them in the cylinder bodies with the 'O' rings and then trying to push the piston through the middle. With that technique there is a danger that you fold or twist the Teflon seal - causing a crease and ruining it. Here is how the manual says it should be done - and it worked:</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">The rubber 'O' for the cylinder body was brushed with LHM and fitted in it's seat. </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL4gO5D2EZ3xfgTZJmUPR7kwzvVwooov7LjFEGk91-zoWeMYKqIH8_PMTddBkAunP5NPwwSBA39ntgCJD6D_qhmyGvnEJzhN7F7WNUc2Ko5DIUEFv67Z7lq13fvOhtcS-RwdlLDYUwHIhDF6KiJIJVX0GwKrRdgKQLCH_ZmjzZvEbBsQJOQsQCMA/s4032/IMG_6729.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL4gO5D2EZ3xfgTZJmUPR7kwzvVwooov7LjFEGk91-zoWeMYKqIH8_PMTddBkAunP5NPwwSBA39ntgCJD6D_qhmyGvnEJzhN7F7WNUc2Ko5DIUEFv67Z7lq13fvOhtcS-RwdlLDYUwHIhDF6KiJIJVX0GwKrRdgKQLCH_ZmjzZvEbBsQJOQsQCMA/w400-h300/IMG_6729.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Rubber 'O' ring in the cylinder body</span><br /></td></tr></tbody></table>The piston was brushed with LHM and the teflon seal was carefully slipped over the open end of the piston.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicrIkQRSpyfO_0RrGznl6Dzv_9Iwt5ikSYBqQVu9_8TwXZQiY5RQrDYQySW7b1ZV2qp4R93zmY4nhhFkfm4kmbacwPxiS2jo4e9KcpMJIoX1vczqsZBnJNYmRO-Rm4HsM7VsHZe-oKF9TsEz9dhyJsmiTQiAzHiIFmv0OMLrVdxpuQKdIriignhQ/s4032/IMG_6731.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicrIkQRSpyfO_0RrGznl6Dzv_9Iwt5ikSYBqQVu9_8TwXZQiY5RQrDYQySW7b1ZV2qp4R93zmY4nhhFkfm4kmbacwPxiS2jo4e9KcpMJIoX1vczqsZBnJNYmRO-Rm4HsM7VsHZe-oKF9TsEz9dhyJsmiTQiAzHiIFmv0OMLrVdxpuQKdIriignhQ/w400-h300/IMG_6731.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Teflon seal on the piston</span><br /></td></tr></tbody></table>The piston, smeared with LHM, was carefully slid into the cylinder body. The top of the piston extends from the cylinder and so the Teflon seal was still visible at this point. I moved it down the piston to the rim of the cylinder - where the 'O' ring was sitting.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">Next the thrust washer was brushed with LHM and slipped over the piston. Carefully pressing down evenly on the thrust washer pressed down on the Teflon ring which suddenly 'popped' into place - between the piston and the iinner circumference of the 'O' ring seal.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizqeEnE6PrafYwTdyVZ-1bX1kCehmD10aDJpPpcd9qOhbsHvoitWun77dK6RvwN8Go7dlTjcSYND0-RfOL8P3t8fRqjKKn8E_Yqf2Bhri_XPUZlOFpqaBhbDGwoFUdE4Jqig6fYG2D-zZWjOVqMe4FjYaHNzomV-F_epETUaSk7Rbao2Qlzz_PEQ/s4032/IMG_6732.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizqeEnE6PrafYwTdyVZ-1bX1kCehmD10aDJpPpcd9qOhbsHvoitWun77dK6RvwN8Go7dlTjcSYND0-RfOL8P3t8fRqjKKn8E_Yqf2Bhri_XPUZlOFpqaBhbDGwoFUdE4Jqig6fYG2D-zZWjOVqMe4FjYaHNzomV-F_epETUaSk7Rbao2Qlzz_PEQ/w300-h400/IMG_6732.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">As if by magic, the white Teflon seal was fitted</span><br /></td></tr></tbody></table>Taking care not to twist the felt seal, the nut was slipped over the piston and screwed up hand-tight. I slipped the nut end back into my vice - again taking care not to over-tighten it. The manual says a force of between 95 Nm and 120Nm sould be applied when tightening the body to the nut. I had no way of measuring that directly so I tightly gripped a large hex-headed nut in another vice and set a torque wrench to 100Nm to get an idea of what applying that force felt like. I then tried to apply approximately the same force through my adjustable spanner. It was all guess work and I can only really say that I felt I did the nut up pretty damn tight.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">I painted a green band around the top of the cylinders. Why? Well I needed to repaint the extension piece that fits to the top of the left hand cylinder anyway. But I don't really know why I painted the bands - other than that there were signs of paint when I took mine apart and I wanted to take them back to the state I think they would have been in originally.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCHQE8shywK4nCM4BDwiEQRtoAKZ07p4GkwmuY2q0IdXsMppTnBrc4f36-nJtSsJUoIzV2OYPiYILoYfXh7q1s9pMbeUJFzlA8lyYcVOZxkHqG9Q7ZWUkGr0ma6EZQ18cLM-VJFvKzyHe-T9PJeTubnqVw-O0-gOWeHQjq5KuCgMqeHojW4S_Lew/s4032/IMG_6695.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCHQE8shywK4nCM4BDwiEQRtoAKZ07p4GkwmuY2q0IdXsMppTnBrc4f36-nJtSsJUoIzV2OYPiYILoYfXh7q1s9pMbeUJFzlA8lyYcVOZxkHqG9Q7ZWUkGr0ma6EZQ18cLM-VJFvKzyHe-T9PJeTubnqVw-O0-gOWeHQjq5KuCgMqeHojW4S_Lew/w400-h300/IMG_6695.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Extension piece and painted band</span><br /></td></tr></tbody></table>I'd bought a single replacement suspension boot from Chyparse -a parts supplier in Holland - back in about 1998. I'd never gotten round to fitting it(!). Now that I needed to replace the pair, I bought two new ones. The various parts sellers often sell a cheaper 'standard' quality version and (because the 'standard' ones aren't very flexible and don't last), a better/ best quality version.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">The pair I bought most recently were 'best quality' apparently. Now I looked at them, i discovered they weren't a 'pair' at all. One was noticibly softer than the other which was stiffer and less springly. I suspected this harder one might actually be a 'standard' quality one....</span><span style="font-family: arial; font-size: small;">The
old Chyparse boot was closer in feel to the softer/ more flexible of
my new 'pair'. What to do? In the end, I decided to fit the two new boots and see if - as suspected - the hard/ less flexible one gave in
first. If it does, I always have the Chyparse gaiter as a spare. I also
decided to refit the two different suspension pushrods and cups. <br /></span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXP0EapjrFwd2orDIQjrzo4S2nfLR3gB10Ls8Nx1LNBJTYc2xJkR5mYyYAgggiZGLE98SbXi1z8bOB0jy_Ln0rKWlIOd0hW8aMvaukxQwFF3oi7l_xzcDlHNIgwP_q9Lv9rR_HxirTUH0trL31kF_Q_YNX9UmvwSQI9F_U1RQzRI9KiB7hUAGAKQ/s4032/IMG_6735.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXP0EapjrFwd2orDIQjrzo4S2nfLR3gB10Ls8Nx1LNBJTYc2xJkR5mYyYAgggiZGLE98SbXi1z8bOB0jy_Ln0rKWlIOd0hW8aMvaukxQwFF3oi7l_xzcDlHNIgwP_q9Lv9rR_HxirTUH0trL31kF_Q_YNX9UmvwSQI9F_U1RQzRI9KiB7hUAGAKQ/w400-h300/IMG_6735.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Not a pair........</span><br /></td></tr></tbody></table><span style="font-family: arial; font-size: small;">With my decisions made, before I fitted the Ligarex bands, I did a 'trial fit' of the cylinders on the car. It's important that </span><span style="font-family: arial; font-size: small;">the
boss where the hydraulic line joins the cylinder is lined up with the
hydraulic pipe. That should be pretty straightforward if you loosely
refit the pinch bolts that hold the cylinder in place - as they will
line up the cylinder. On my car, on the left had side the boss faces
backards - towards the cabin. On the right hand side the boss faces
forward towards the bumper. Relative to the cylinder position, it's also important that the slot through the cup of the pushrod is lined up to the split pin holes in the suspension on the car. With the boot joing these two parts together, there is one last check to make: that the overlflow outlet of the boot is lined up with the rilsan overflow pipe on the car.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">With the alignments made, I fitted the Ligarex bands. Over the gaiters themselves, I fitted new rubber belts so that the Ligarex bands did not bite into the boots. <br /></span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAmqLIGcp6dzMx704uAwT-5VcrR0L9cwwbc6fry_uKnHRM-5INq9X5zDf6Y5loicoWnS16FGtebnqRxFspAAuwF_QGwCuWRsr53F9zvZsET__zqAVNG5ja-Py5kaUoZ_HiCW78qG4s1atU29NIy5AMxwEb9PU3aEXjSirkuOhbz2lwnngiRnG6tw/s4032/IMG_6764.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAmqLIGcp6dzMx704uAwT-5VcrR0L9cwwbc6fry_uKnHRM-5INq9X5zDf6Y5loicoWnS16FGtebnqRxFspAAuwF_QGwCuWRsr53F9zvZsET__zqAVNG5ja-Py5kaUoZ_HiCW78qG4s1atU29NIy5AMxwEb9PU3aEXjSirkuOhbz2lwnngiRnG6tw/w400-h300/IMG_6764.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Ligarex bandings fixed</span><br /></td></tr></tbody></table><span style="font-family: arial; font-size: small;">The only fiddly bit of fitting the cylinders was fitting the split pins through the cups at the bottom. I used new split pins but they were a tight fit in the holes so needed to be lined up perfectly. <br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmh6RR17mwdnwwEWMobQBA4CTmc8cPrL1gDzLXHavaA8iLOy62rUnoLgGscwVNGQE8kgUIfBIq6AhE01s3Db4-xGb0KPxYPSj9hSXHYmIUPiQsNX7B6-UjxFDM5E6AzNwjxAo4z_KN4FGPtvo4q10Wsj9KlGHzp1T3ZFh-sRwlTlaoyDvoKwRttg/s4032/split%20pin.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmh6RR17mwdnwwEWMobQBA4CTmc8cPrL1gDzLXHavaA8iLOy62rUnoLgGscwVNGQE8kgUIfBIq6AhE01s3Db4-xGb0KPxYPSj9hSXHYmIUPiQsNX7B6-UjxFDM5E6AzNwjxAo4z_KN4FGPtvo4q10Wsj9KlGHzp1T3ZFh-sRwlTlaoyDvoKwRttg/w400-h300/split%20pin.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Split pin at the base of the suspension cylinder</span><br /></td></tr></tbody></table>With that done, there are two bolts and lock nuts that hold the sides of each cylinder. These are not meant to be done up tightly. </span><span style="font-family: arial; font-size: small;">These have pointed end. </span><span style="font-family: arial; font-size: small;">They should only be done up hand tight so that the pointed ends engage in the dimples in the cylinder bodies. Then the lock nuts are tightened.</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWxb3j4qkkaCywgj0qqaBGx4KwcD4k2KGnY_NeZRADl0mWXbx2R9_HEUysJ--nzNqZnZ5euMwq2UJrT23NOQLTOd0yD5HPfn6Mbs9k2gVgOHg2iWy6QbLMzMOv8GyNLFtZSef-mTW7qCQbh-HZEXCj1TPyR6hAmpS46iEWcveXkxyfXYIQ8AJX5w/s4032/Bolt.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWxb3j4qkkaCywgj0qqaBGx4KwcD4k2KGnY_NeZRADl0mWXbx2R9_HEUysJ--nzNqZnZ5euMwq2UJrT23NOQLTOd0yD5HPfn6Mbs9k2gVgOHg2iWy6QbLMzMOv8GyNLFtZSef-mTW7qCQbh-HZEXCj1TPyR6hAmpS46iEWcveXkxyfXYIQ8AJX5w/w400-h300/Bolt.jpg" width="400" /></a></div><span style="font-family: arial; font-size: small;">If I get a suspension leak from one or other boot, I have a spare to fit. When I'm setting up my front anti-roll bar, if that proves difficult then I will have to try and remember that the two suspension pushrods are not quite the same length.<br /></span></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-75394568878489687072023-04-28T15:37:00.000+00:002024-01-21T17:23:41.211+00:00Dashboard Air Ducts<div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">When I revisited my car after it's long slumber, one of the things that most disappointed and troubled me was, on the surface of it, a small thing. The rusted chrome levers of the air duct controls. Being part of the dashboard they're right there - in your face when you sit in the car, and so fixing these felt like an important part of my restoration.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcrVRbZT0QG7L8wE70Q8PP8zGBpRFXegaSKVXDXIlzQ67G3Fb3FmhLSw_K3xNSFFr9tQ764xTySv-Jtn4kYcrrrvC4KKw0VBdOtRO7HdvzAyL93sRqdlA3d90lIQq5QOveJnk3_I6g6fqVSb1rq1zQzSPoWCWh-AF-XBZlB3f_jDoLhHuGcWonmD7Z/s4032/IMG_6200%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcrVRbZT0QG7L8wE70Q8PP8zGBpRFXegaSKVXDXIlzQ67G3Fb3FmhLSw_K3xNSFFr9tQ764xTySv-Jtn4kYcrrrvC4KKw0VBdOtRO7HdvzAyL93sRqdlA3d90lIQq5QOveJnk3_I6g6fqVSb1rq1zQzSPoWCWh-AF-XBZlB3f_jDoLhHuGcWonmD7Z/w400-h300/IMG_6200%20copy.jpg" width="400" /></a></div>I wasn't sure what I would need to do, but over the several years, and many varied jobs of the restoration, when I thought about putting the dashboard back in, the thought of how to 'make good' on the air duct levers was never far from my mind.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSmN0rIqt0esUCDhqqfByOcm-FLEqfENkWSFS4sIrHA5n0Pk_5HxBu-fPvLZbhAiM7iS_PpaLb2HZNTjSc3Vbl6uM4FHAFEjeoFglUe_XPQ7lZ_kVCh6puc8u6OJ29IODeG8P5l4r-051fFlf6DWZMHnFIYB7HhSkF4ykNJEhuAcCOC2RqkV_T4DB2/s3264/IMG_8386.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSmN0rIqt0esUCDhqqfByOcm-FLEqfENkWSFS4sIrHA5n0Pk_5HxBu-fPvLZbhAiM7iS_PpaLb2HZNTjSc3Vbl6uM4FHAFEjeoFglUe_XPQ7lZ_kVCh6puc8u6OJ29IODeG8P5l4r-051fFlf6DWZMHnFIYB7HhSkF4ykNJEhuAcCOC2RqkV_T4DB2/w400-h300/IMG_8386.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Rusty levers......</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">Eventually I pulled the dashboard from the car back in November 2018. <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpXVmJtUfMeGZnluRdqpWdd57tplfeEnbP-tWWr8Rrgxau4ReeIvfrs4f1Zis_mLIzt9RiA7S17dZtZXhSwb7uRdYlMunDQcjdlRrQOoijvbKf5ieTka8oVjJVYjEccvu1mmfHv68QtLWtlFD6eDHydw7g70lyJsJ-TALr4SCsgiVDZh3wOKiZWZSi/s3264/IMG_8363.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpXVmJtUfMeGZnluRdqpWdd57tplfeEnbP-tWWr8Rrgxau4ReeIvfrs4f1Zis_mLIzt9RiA7S17dZtZXhSwb7uRdYlMunDQcjdlRrQOoijvbKf5ieTka8oVjJVYjEccvu1mmfHv68QtLWtlFD6eDHydw7g70lyJsJ-TALr4SCsgiVDZh3wOKiZWZSi/w400-h300/IMG_8363.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Dashboard removed. Note all the dust and dirt</span><br /></td></tr></tbody></table></span></span><span style="font-size: small;"><span style="font-family: arial;">With the dashboard removed, the air ducts were exposed.. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqtv_j0lvEK8aE4JNZejyCXvM3VBuk-rgYDyh0OkgMkEpdk2MenRg0XQ-OYs14bQ0n5KoBIbRaIkUrlik7Cs8inOSNn2Vi9EX8kgcXFz4L8cRjXQe7VYZbIHnM47NWklAv_zJkE4uR4Efhrl-meBWKUERl0Dqj21nln0bgPCj3o8EbWdyZBzYm4Bw2/s1002/Dashboard%20fixings%20on%20a%2068.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="640" data-original-width="1002" height="255" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqtv_j0lvEK8aE4JNZejyCXvM3VBuk-rgYDyh0OkgMkEpdk2MenRg0XQ-OYs14bQ0n5KoBIbRaIkUrlik7Cs8inOSNn2Vi9EX8kgcXFz4L8cRjXQe7VYZbIHnM47NWklAv_zJkE4uR4Efhrl-meBWKUERl0Dqj21nln0bgPCj3o8EbWdyZBzYm4Bw2/w400-h255/Dashboard%20fixings%20on%20a%2068.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">An air duct in situ. (Photo credit unknown)</span><br /></td></tr></tbody></table> They </span></span><span style="font-size: small;"><span style="font-family: arial;">can be unbolted from underneath and pulled forward into the cabin. They </span></span><span style="font-size: small;"><span style="font-family: arial;">need to be twisted a little to manoeuvre them out, and untangled from hoses, cables and the wiring loom. It helps to first remove the foam seals on the engine bay side. <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIvDoppY62PKt6P-il0Nk1jX18EhZCdzvHPDm-LWAMzLhkWsVlTjDQONJslD51B3ObIofCmDm-r8HWzPl2oOpdZcfkSq5LE57FY7hiXJYYRgCkjOgvF0JexgM9J8rSfwn4C6N7O5yEQYRLAdqkn-_caY5yztJC922zI-nRNBh1x7JEli80jO9m5t9D/s3264/IMG_8364.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIvDoppY62PKt6P-il0Nk1jX18EhZCdzvHPDm-LWAMzLhkWsVlTjDQONJslD51B3ObIofCmDm-r8HWzPl2oOpdZcfkSq5LE57FY7hiXJYYRgCkjOgvF0JexgM9J8rSfwn4C6N7O5yEQYRLAdqkn-_caY5yztJC922zI-nRNBh1x7JEli80jO9m5t9D/w400-h300/IMG_8364.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;"><span style="font-family: arial;">Removing an air duct with a twist...</span><br /></span></td></tr></tbody></table></span><span style="font-size: small;"><span style="font-family: arial;">The ducts on pre-1968 cars seem to have been made of metal. Mine are plastic. I think they were fitted for two years before the later three dial dash was introduced for the 1970 model year and a new duct design was needed.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">The two levers control the input of air into the cabin via flaps inside the units. <br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzYTkf-UXyoEJKyCxr_LlOMilQvaal_HY87joFW_bbg8TM2nQWve6jXCOomymG_WONmgqp_Fhn1Si785J24uL-8Y2ZjjOJDueYoPNqNs2oXln8QBTTAI9EqwwZ230aG58x-bs617bA0H-NvrzmnjF9N2Z-2tJgYAsGI1jDy7v6puFq59RhjPGdyyn2/s4032/IMG_7837.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzYTkf-UXyoEJKyCxr_LlOMilQvaal_HY87joFW_bbg8TM2nQWve6jXCOomymG_WONmgqp_Fhn1Si785J24uL-8Y2ZjjOJDueYoPNqNs2oXln8QBTTAI9EqwwZ230aG58x-bs617bA0H-NvrzmnjF9N2Z-2tJgYAsGI1jDy7v6puFq59RhjPGdyyn2/w400-h300/IMG_7837.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The levers and grille....</span><br /></td></tr></tbody></table>Through a series of articulating joints and elbows, the levers pull on cables that operate the flaps to channel the air. </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAAvG7hPQHESeVBl0h5uk_T6I6F8CSXOrjnniCcqz_rrddjtqxpyvVawCQcf8Lqh_MQLT52zDdWuuCdNOqOyv-s5vBOsV_Dqz3E0goDrDvVz8kyUxg5xIwWav4ammL4CNf9SZ9RcHfUnXw2GirusD5g7pesG-aRnm2Ilebc8C1ZwG9-kQsOxB9DVsu/s4032/IMG_7838%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAAvG7hPQHESeVBl0h5uk_T6I6F8CSXOrjnniCcqz_rrddjtqxpyvVawCQcf8Lqh_MQLT52zDdWuuCdNOqOyv-s5vBOsV_Dqz3E0goDrDvVz8kyUxg5xIwWav4ammL4CNf9SZ9RcHfUnXw2GirusD5g7pesG-aRnm2Ilebc8C1ZwG9-kQsOxB9DVsu/w300-h400/IMG_7838%20copy.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The two flaps inside each duct</span></td></tr></tbody></table>One flap divides air between the cabin and dashboard. And for the air coming to the dashboard, and the other flap controls the volume. </span><span style="font-family: arial; font-size: small;">A pivoting grille can be used to angle the direction of the dashboard air.</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">The earlier ducts are made of pressed and folded metal. </span><span style="font-family: arial; font-size: small;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinsNe-9k9m8dDvzrCGopR57hok7jVnUTJ4iEJdLmZcfIFNodqRAZ_6AhuRMLF9tis6CoXRIcMC0y-6q87vOKT7H_ieZX_bmmz5_QlIVv6ZfWnKv3sXY-dElPkB9T3NF91m1wk5f393UnVgQh-xl-Lm4ex-XrY_6zfaFNvHrV6ZV6Bo_87d1vV0rXrV/s1003/ventilator%20diagram.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="774" data-original-width="1003" height="494" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinsNe-9k9m8dDvzrCGopR57hok7jVnUTJ4iEJdLmZcfIFNodqRAZ_6AhuRMLF9tis6CoXRIcMC0y-6q87vOKT7H_ieZX_bmmz5_QlIVv6ZfWnKv3sXY-dElPkB9T3NF91m1wk5f393UnVgQh-xl-Lm4ex-XrY_6zfaFNvHrV6ZV6Bo_87d1vV0rXrV/w640-h494/ventilator%20diagram.jpeg" width="640" /></a></div>The plastic duct housings are riveted together and I wanted to avoid taking them apart - for fear of breaking the plastic on disassembly or assembly<br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">The operating levers were actually outside of the housings and a closer examination showed that the shafts that the levers were on were only held in place by circlips. In other words the levers could be removed. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj20MbwY-sLbUJ8FoVRfVI752qT6sg-qNpvLS-6mW7O4DL-EKCtiHcb715xujikU4Yt296thUCkYtcyIK2P6cCexd1lQ-3mMzbL-XsDqHZzHnfDi1yVyZSc2k7wdyELkaqV-6vq7iTKnL6F37vkWscQDGtb9bh2ooFbJXL2yqIn34vInAObAfEf2om2/s3264/IMG_8399%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj20MbwY-sLbUJ8FoVRfVI752qT6sg-qNpvLS-6mW7O4DL-EKCtiHcb715xujikU4Yt296thUCkYtcyIK2P6cCexd1lQ-3mMzbL-XsDqHZzHnfDi1yVyZSc2k7wdyELkaqV-6vq7iTKnL6F37vkWscQDGtb9bh2ooFbJXL2yqIn34vInAObAfEf2om2/w300-h400/IMG_8399%20copy.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The levers are held on by circlips and spring washers</span><br /></td></tr></tbody></table><span style="font-family: arial; font-size: small;">It was right back in November 2018 that I gingerly went about this job.</span><span style="font-family: arial; font-size: small;"> It involved carefully unhooking the control lines and connectors that operated the flaps inside the units......</span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxBkVDAcMC-5bjoY8bQLVFNim9-fS0ruCH4M5prAebVc1NJqjnbDts4xWzT94LG3uFGAnHeoqyByB30Vac7ZC4xK__mKmFnIJDrWo5_wuKmVya2QJ73vSa2JSovt51zFKD1XOShqA81CmelpXO_PT2KQsz3CWqEw8bfQWnCwz5JMkxfmK-dQFTW1rG/s3264/IMG_8394.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxBkVDAcMC-5bjoY8bQLVFNim9-fS0ruCH4M5prAebVc1NJqjnbDts4xWzT94LG3uFGAnHeoqyByB30Vac7ZC4xK__mKmFnIJDrWo5_wuKmVya2QJ73vSa2JSovt51zFKD1XOShqA81CmelpXO_PT2KQsz3CWqEw8bfQWnCwz5JMkxfmK-dQFTW1rG/w400-h300/IMG_8394.JPG" width="400" /></a></div>......removing the ciclips and winkling the shaft out.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpdMxLC0HG_8xz_izZmg7AKhXdNbJ0FMMeVa16KLMCoWmW6GzCiKL2asVDovZ6dcVJY1V68sEE_e3vWnOltpnlUZkBJFWN2iX9Z1oyCRV4S0CCeLxpE-HtRg3IbHA1aNcx6Zg6_gOKip8UkJ1rhWCTQ06dF1LafWlGIN84nd883JpAAxCFaza4HcPz/s3264/IMG_8377%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpdMxLC0HG_8xz_izZmg7AKhXdNbJ0FMMeVa16KLMCoWmW6GzCiKL2asVDovZ6dcVJY1V68sEE_e3vWnOltpnlUZkBJFWN2iX9Z1oyCRV4S0CCeLxpE-HtRg3IbHA1aNcx6Zg6_gOKip8UkJ1rhWCTQ06dF1LafWlGIN84nd883JpAAxCFaza4HcPz/w400-h300/IMG_8377%20copy.jpg" width="400" /></a></div> <br /></span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFi3KtgafM200YIn5AEncINljHN1tfv8JCbmQzjTV1tyVcyiWatDrfWp5Ungw311oUbAzdqfu3uFGrqb8jNjJBB772XFNHVcQrtqS9_xNlhqQOkYyjhmus2iipYXPfyfcdeDIcdusRf_0ZZxiDW09F9CAMthwn4C4trjURJA0l-y96gg6OeMwdJOKB/s3264/IMG_8391%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFi3KtgafM200YIn5AEncINljHN1tfv8JCbmQzjTV1tyVcyiWatDrfWp5Ungw311oUbAzdqfu3uFGrqb8jNjJBB772XFNHVcQrtqS9_xNlhqQOkYyjhmus2iipYXPfyfcdeDIcdusRf_0ZZxiDW09F9CAMthwn4C4trjURJA0l-y96gg6OeMwdJOKB/w400-h300/IMG_8391%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Lever mechanisms removed</span><br /></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">Each lever has a spring-loaded ratched to help the lever hold it's set position and these simply slid off the shafts. But what to do next?</span><br /></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUz9hXEhYBXixltd8Hgwh4wS5K1xnSZjIdcNBImHk1OI2fNfe_W-hE87JGSiBjx3mfswgWb73ca652Jl7GNVE_s8PsgN7bUNdH9ojCaETxZxl0EKOYB3vL2wVqpH0uyStwuq2WHDkkLkAUBgw-jA4202pVdEtKVBxBnyPFSZgGknWYtP_8EPMZI8_3/s3264/IMG_8378%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUz9hXEhYBXixltd8Hgwh4wS5K1xnSZjIdcNBImHk1OI2fNfe_W-hE87JGSiBjx3mfswgWb73ca652Jl7GNVE_s8PsgN7bUNdH9ojCaETxZxl0EKOYB3vL2wVqpH0uyStwuq2WHDkkLkAUBgw-jA4202pVdEtKVBxBnyPFSZgGknWYtP_8EPMZI8_3/w400-h300/IMG_8378%20copy.jpg" width="400" /></a></div>I did think about getting them re-chromed just as they were. After all, the chrome would not take to the plastic. However I had heard that removing and re-chroming was quite a physical process and might involve grinding and/ or polishing. That might damage the plastic parts. Looking more closely, I deeemed the plastic to be some kind of nylon or polythene rather than a hard plastic. </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">The chromed lever shafts have a flat spot where the knobs are fitted at a particular orientation and so clearly the levers need to be prevented from rotating in their plastic bases. But how were they fitted?<br /></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;">I tried to unscrew them - no dice - so i set about carefully trying to pull one off. Reasoning that the metal shaft would need to be cleaned and de-burred anyway, I carefully gripping the end of the shaft in a vice, close up to where the shaft disappears into the plastic piece. I used the cleft in a small jemmy to lever the plastic piece off againt the head of the vice jaw. Slowly but surely it starterd to move. It was a very satisfying feeling: like pulling the cork from a bottle. 'Slow' was also good as it reduced the risk of the jemmy marking the plastic piece. As the shaft eased out, a bulge appeared. The shaft had been squashed flat(ter) so that it held firm in the plastic piece. <br /></span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrpCXS4CNAcik-c60fRSpnTo0KHSaH03RiYpuVeEsbLP3eZaUk_8bf98EQTPJFipKIbeEimPFd8UvTrfnO5Q4V4R8IxXDhoAzZRuk2gO8LONjvgjD75CpzzP6TI3XZzhFfALjCjY6FxCvG82cn5yKJRFzE0361Fakc9o7t5vrtgwNa4KUZ-CmVYQn0/s3264/IMG_8400.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrpCXS4CNAcik-c60fRSpnTo0KHSaH03RiYpuVeEsbLP3eZaUk_8bf98EQTPJFipKIbeEimPFd8UvTrfnO5Q4V4R8IxXDhoAzZRuk2gO8LONjvgjD75CpzzP6TI3XZzhFfALjCjY6FxCvG82cn5yKJRFzE0361Fakc9o7t5vrtgwNa4KUZ-CmVYQn0/w400-h300/IMG_8400.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Ignore the ruler. Notice the bulge</span><br /></td></tr></tbody></table><span style="font-family: arial; font-size: small;">Once
removed it was clear that, before chroming,each shaft had simply been
squashed in a press in two places so that it bulged at particular
points. The hole in the plastic piece was probably just a straight hole -
nothing fancy. After chroming the shaft had been pressed into the
polythene piece (which yeilded slightly to accomodate it) and the bulge
in the shaft stopped it rotating.</span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;">With more confidence I carefully went about removing the other three shafts.This is what I was left with.</span></div><div style="text-align: left;"><div style="text-align: left;"><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLq5-BwefyQKr0MaFVNUMgPtlywsp7pTnKueP5GOakdTQaW3DSGwMUC1U_1GETMWtZTNAzIkEHxG0zXeWx48RW6uMbJqfAr9Cuq9B9V43q-aDM4zG1DVpsZC1viDDPLX0Ivpul-JKazmYQ8nYsJUygoOu-xdij-sb3omWvxRORONjQYhyphenhyphendl575Ckxi/s3264/IMG_8388.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLq5-BwefyQKr0MaFVNUMgPtlywsp7pTnKueP5GOakdTQaW3DSGwMUC1U_1GETMWtZTNAzIkEHxG0zXeWx48RW6uMbJqfAr9Cuq9B9V43q-aDM4zG1DVpsZC1viDDPLX0Ivpul-JKazmYQ8nYsJUygoOu-xdij-sb3omWvxRORONjQYhyphenhyphendl575Ckxi/w400-h300/IMG_8388.JPG" width="400" /></a></div></span><div style="text-align: left;"><span style="font-family: arial; font-size: small;"> </span><span style="font-family: arial; font-size: small;">At this point it's worth pointing outo that two lever shafts are longer than the other two.</span></div></div></div></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1GCnW4Yf_C0drmp4YzVHQDDwQudIpw55IEXrnHQ68yBSbvPdB5sNc6Y2qYkSifINqTntMg5A_lXcvQ0b4iQ2f_0ZQ9Q40ASFSnaNdq0yw6c_tlVGuTtWaBcGBMcY7sAW1JV9uqxgrwkjscaraYEfUrL_16C9nYdkN6jGIjrxxR9fO72elqJDZ19lg/s3264/Four%20heater%20control%20rods.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1GCnW4Yf_C0drmp4YzVHQDDwQudIpw55IEXrnHQ68yBSbvPdB5sNc6Y2qYkSifINqTntMg5A_lXcvQ0b4iQ2f_0ZQ9Q40ASFSnaNdq0yw6c_tlVGuTtWaBcGBMcY7sAW1JV9uqxgrwkjscaraYEfUrL_16C9nYdkN6jGIjrxxR9fO72elqJDZ19lg/w400-h300/Four%20heater%20control%20rods.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Notice that one pair of shafts is longer than the other</span><br /></td></tr></tbody></table>The
shorter pair are for the vent on the 'flat' driver side of the dash.The longer levers go on the passenger side and accomodate the curve in
the dash and the metal vent outlet cover. </span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnTN4cgIHpK_6DUv1UgAi6nPQNYVyJWUxXBHYmOE5inenTdricBcYnj0r1-fQiW1zr4w7lCZkTsTgqhlLuLDrFXuA1d_Fx2GdzPUAOHijvZZzg0HRIGNccRwkcd1pEBuvvHEjt5P8ygjMXvVXHrNKixiD7_c3kfCcz58WfweK49z-g_W4g7WQLXj-b/s2331/My%20DS21%20dash%20circa%201995.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1608" data-original-width="2331" height="276" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnTN4cgIHpK_6DUv1UgAi6nPQNYVyJWUxXBHYmOE5inenTdricBcYnj0r1-fQiW1zr4w7lCZkTsTgqhlLuLDrFXuA1d_Fx2GdzPUAOHijvZZzg0HRIGNccRwkcd1pEBuvvHEjt5P8ygjMXvVXHrNKixiD7_c3kfCcz58WfweK49z-g_W4g7WQLXj-b/w400-h276/My%20DS21%20dash%20circa%201995.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The ventilators are at each end of the dshboard</span><br /></td></tr></tbody></table>Together with a few other pieces, I sent the levers away to Derby in summer 2019 to be chromed. That wasn't cheap, but they came back looking great. </span><span style="font-family: arial; font-size: small;">However it wasn't until February of this year, and with the engine bay all painted up, that I thought about re-assembly. </span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"> </span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;">The first thing I needed to do was to clean the plastic duct housings. These had accumulated a load of oily dirt over the years and this was visible from within the cabin. Particulary so the 'grille' pieces.</span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0ah0nYzvDGnyIZcP2WGiAn53xvmYGTTV1Q98RL4iHNnhVJtnFVWWB9yElCcpn1QPyqXVjV0PlLvooCVNXiwXMIJCm2CXXh1BD3crXCu3wpLLPMtA6f7QrWWpFrkmPGDhNXYuTTyREiJm1NKunVws-fsSruAHvtGOX4TTl0DanV54c8wfGPqDpnFws/s3264/IMG_8390.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0ah0nYzvDGnyIZcP2WGiAn53xvmYGTTV1Q98RL4iHNnhVJtnFVWWB9yElCcpn1QPyqXVjV0PlLvooCVNXiwXMIJCm2CXXh1BD3crXCu3wpLLPMtA6f7QrWWpFrkmPGDhNXYuTTyREiJm1NKunVws-fsSruAHvtGOX4TTl0DanV54c8wfGPqDpnFws/w400-h300/IMG_8390.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: small;"><span style="font-size: x-small;">Dirty grille......</span></span></td></tr></tbody></table> I didn't want to unrivet the halves and so worked with twith them as they were.<br /></span><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><br /></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;">As the operating cables were set up to operate the flaps correctly I left these alone. But because of this, I didn't want to immerse the units in water. Instead, I worked around the cables. I used a damp tooth brush to clean out the hinged grille pieces. Reaching inside, I used a damp cloth to clean the flaps and innards. I used compressed air to both dry them and blast out any dirt remaining. Finally I offered up a tiny bit of grease to the moving parts. <br /></span></div></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><br /></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;">They cleaned up well and the ducts looked almost like new. Almost......The bodies looked as though, in addition to rivets, an attempt had been made to glue the halves together - well certainly along the top edges. </span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiN1YD6UWbiJjFAKMDH-gZcG1cj_xP5ODnlqxAtfgQbAz1kOe-vPbS56MHjjywO1bCr1hlrMGfgx41fQjPBcpO8C6ucxxdHHUAb9K4QK8jr1SzMpxcZ5z6hK8dyiS04TIkXWXJu_jJiy_N8AZCpdVroYdB90woB6xJFNbPgGM-7y6keZrmJr2-TxLpT/s4032/IMG_7839.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiN1YD6UWbiJjFAKMDH-gZcG1cj_xP5ODnlqxAtfgQbAz1kOe-vPbS56MHjjywO1bCr1hlrMGfgx41fQjPBcpO8C6ucxxdHHUAb9K4QK8jr1SzMpxcZ5z6hK8dyiS04TIkXWXJu_jJiy_N8AZCpdVroYdB90woB6xJFNbPgGM-7y6keZrmJr2-TxLpT/w400-h300/IMG_7839.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Signs of glue?</span><br /></td></tr></tbody></table>It was quite messy but I resisted the urge to try and tidy this up. </span><span style="font-family: arial; font-size: small;">There were no indications that the duct hosuings were broken or that, without the glue, they might leak. </span><span style="font-family: arial; font-size: small;">Plastic can be hard to work with, and these kind of jobs have a risk of going wrong. Instead, I decided to love my ducts units - glue and all.</span></div><div style="text-align: left;"><p style="text-align: left;"><span style="font-family: arial; font-size: small;">On to reassembly of the lever mechanisms. A key point here was to make sure I matched the right shafts, to the right plastic pieces..... <br /></span></p></div><p style="text-align: left;"><span style="font-family: arial; font-size: small;"></span></p><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: left;"><tbody><tr><td style="text-align: center;"><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNWzzNQJlpolzeGG_ZY8UvvIeu45CC0CZeQQlSKTIzOf_GimFjyvkR35N6ttwHdCNuH7Z0GP5kpqCdnNdONs1ChUfRVbeT6cQTsnTEmJx24X5jAIUTGOlSIyUEqTy_Nm7H25xGDe4bpbK0w2y-dty0U-cmY-2TSYMHG-KHEwLU8lDH0_TIh5MHpfGW/s4032/IMG_6194.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNWzzNQJlpolzeGG_ZY8UvvIeu45CC0CZeQQlSKTIzOf_GimFjyvkR35N6ttwHdCNuH7Z0GP5kpqCdnNdONs1ChUfRVbeT6cQTsnTEmJx24X5jAIUTGOlSIyUEqTy_Nm7H25xGDe4bpbK0w2y-dty0U-cmY-2TSYMHG-KHEwLU8lDH0_TIh5MHpfGW/w400-h300/IMG_6194.JPG" width="400" /></a></div></td></tr><tr><td class="tr-caption" style="text-align: center;"><p><span style="font-family: arial; font-size: x-small;">Ready for reassembly</span></p></td></tr></tbody></table><div style="text-align: left;"><span style="font-family: arial; font-size: small;">......and to make sure the shafts are orintated correctly for the two black knobs on the ends.</span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"></span><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNKiO5UVlYanFR3nMH_ctq3A-43JsbYHZoym2Wm2bCxJA4h0PuB86FUI14jMOOrrVmfvq07pMLrG65BOSVicwx6VANuDDWBXbTrXrZmUw6NI9IHHHxuVPeiK2lu8BZx81Axj3TxNF1eWa7owCO-mYgerA82Gmhctqcnmq2igGgAYHIfPLobO5nsoXg/s4032/IMG_6201%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNKiO5UVlYanFR3nMH_ctq3A-43JsbYHZoym2Wm2bCxJA4h0PuB86FUI14jMOOrrVmfvq07pMLrG65BOSVicwx6VANuDDWBXbTrXrZmUw6NI9IHHHxuVPeiK2lu8BZx81Axj3TxNF1eWa7owCO-mYgerA82Gmhctqcnmq2igGgAYHIfPLobO5nsoXg/w400-h300/IMG_6201%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Orientation of the shafts on the levers. Note the 'flat spots'</span><br /></td></tr></tbody></table></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"> The
knobs need to face out from each other - so that they don't get in each
others way. </span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhm4wr3x7HWJGF2OtTNvRJ06e_x0McmqPH2Hqxz1Xu2bz7n4w4lfO5ikFHh3DZNQeusCWPcsrvRXg9Oo74vKi8nznPlVaLwDczE_l366b69iQWBkaPx0YUAmS5nDDbTjUoxzokiFW7Z6VSlUcIAq_AbTE21I9sW-c0qBzufc4k6KYnDEmF0d3zrWUox/s4032/IMG_7846.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhm4wr3x7HWJGF2OtTNvRJ06e_x0McmqPH2Hqxz1Xu2bz7n4w4lfO5ikFHh3DZNQeusCWPcsrvRXg9Oo74vKi8nznPlVaLwDczE_l366b69iQWBkaPx0YUAmS5nDDbTjUoxzokiFW7Z6VSlUcIAq_AbTE21I9sW-c0qBzufc4k6KYnDEmF0d3zrWUox/w400-h300/IMG_7846.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Lever knobs face out</span><br /></td></tr></tbody></table>So, carefully orientating the lever to the plastic bush, I used my bench vice to slowly squeeze the two together. The risk here is that the bulges in the shaft cause the bush to crack and split but by working slowly, I hoped to reduce any 'shock'.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhU2DIvgpHeXO-GEzhVvBwFRmtpwyIuFc9_gMg3v3zMP_OsIPDnaBpzI47brQPouT6q2UGcshyphenhyphenvgfM9-aC4pqzX-QcEjUpAYeomxZfLRaFShyphenhyphen9CC8NQddnNelMBP1US0WNCSinvirt_Qp234leZix0ygdc9gsIlP6YPTpWLUy81fY2QAjo5c6x-JZnp/s4032/IMG_6197.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhU2DIvgpHeXO-GEzhVvBwFRmtpwyIuFc9_gMg3v3zMP_OsIPDnaBpzI47brQPouT6q2UGcshyphenhyphenvgfM9-aC4pqzX-QcEjUpAYeomxZfLRaFShyphenhyphen9CC8NQddnNelMBP1US0WNCSinvirt_Qp234leZix0ygdc9gsIlP6YPTpWLUy81fY2QAjo5c6x-JZnp/w400-h300/IMG_6197.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Using a vice to refit the lever to it's plastic bush</span><br /></td></tr></tbody></table><span style="font-family: arial; font-size: small;"> </span><span style="font-family: arial; font-size: small;"><br /></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKnzSns-6sFok3wtnpmNgBDHRY7aDGtP5DpmHd_Wt-MuadaX6RVTIGS08p8x0fH5JDDhKzrNN14aXZhKhQFNuuwJlSVzDvVuc-4KYECIzbngcj1Wgri42AGgjp45D2_i8hvLmPrg3RLFC3iMZ8erWE9octIUfjG1wPo4BsAVUmD1ApHOQ3P2yM4CId/s4032/IMG_6199.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKnzSns-6sFok3wtnpmNgBDHRY7aDGtP5DpmHd_Wt-MuadaX6RVTIGS08p8x0fH5JDDhKzrNN14aXZhKhQFNuuwJlSVzDvVuc-4KYECIzbngcj1Wgri42AGgjp45D2_i8hvLmPrg3RLFC3iMZ8erWE9octIUfjG1wPo4BsAVUmD1ApHOQ3P2yM4CId/w400-h300/IMG_6199.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Slowly pressing the shaft onto the plastic bush</span><br /></td></tr></tbody></table></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;">It was hard to remember how everything went back to gether after so long and I relied on photos I had taken back then. It was a case of lining all the levers and arms up and then slipping the 'axle' in, before fitting the circlips. When all was done they looked much smarter than they had done when I'd removed them.</span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2ze83KSs25qGXE9HUconQZxigfNWEmDH2xbPyJ8FpHTyhf4aKE5-qxNMLAbvwUvvNZ76THYGffaMKhMGffNZ7MMLi8wr02453G_xd6PVYt28GVlLflI0Dzf_xxivRsL2-fhEaxWhicutmPxDnCtRsc4fK5uTe1sIXw-f_YzbN7pB1So9QNAAeyAG7/s3264/IMG_8385.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2ze83KSs25qGXE9HUconQZxigfNWEmDH2xbPyJ8FpHTyhf4aKE5-qxNMLAbvwUvvNZ76THYGffaMKhMGffNZ7MMLi8wr02453G_xd6PVYt28GVlLflI0Dzf_xxivRsL2-fhEaxWhicutmPxDnCtRsc4fK5uTe1sIXw-f_YzbN7pB1So9QNAAeyAG7/w400-h300/IMG_8385.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Before....</span></td></tr></tbody></table>Come early March and I was ready to refit them on the car. I offered each one up from the engine bay side. Before I screwed them in place, I cleaned and refitted the foam rubber seals that close the gaps around them. I had even tagged them back in 2018 so I could put them back on the same sides they'd been removed from! These fit in from the engine bay side and are shaped to fit the lip of the holes in the bulkhead. <br /></span></div><p><span style="font-family: arial; font-size: small;"></span></p><div class="separator" style="clear: both; text-align: center;"><span style="font-family: arial; font-size: small;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCwgDaB4Icjit-4y0F73XdMJyKtBZWQv7NSaUOrzG-4LNRSbqFmi71sn25nDBpKBs5ntwBrhWz22rICN74JG5xbza08yo_VQVOydJe50ZJ2Qs6ILpaCTSZaRtPapM_IfuvAI53LmS1wZlOrHbxsKTGmtBWXTufNAwzb2imrWucbkatX4DjhMR2w33m/s4032/IMG_6136.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCwgDaB4Icjit-4y0F73XdMJyKtBZWQv7NSaUOrzG-4LNRSbqFmi71sn25nDBpKBs5ntwBrhWz22rICN74JG5xbza08yo_VQVOydJe50ZJ2Qs6ILpaCTSZaRtPapM_IfuvAI53LmS1wZlOrHbxsKTGmtBWXTufNAwzb2imrWucbkatX4DjhMR2w33m/w400-h300/IMG_6136.JPG" width="400" /></a></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"> They take a bit of fiddlig to get them looking nice.</span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBgk6IhsRB0BGYEdeyaQTLecwzvsQL_p055l8GaXhNzIs3_REFWpu0fcma1lvzBoexN3idWIa6BIZJifPHRpVvTHhQ2Ndnpc3Yooadwn7as_M8UgvVIeWblVXmlA9g9daWTcFyXRqQleqTTUBiOfBcN8q06QxTHZB2jDWxryxkM1cXAD8LI-4G_H8a/s4032/IMG_6203.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBgk6IhsRB0BGYEdeyaQTLecwzvsQL_p055l8GaXhNzIs3_REFWpu0fcma1lvzBoexN3idWIa6BIZJifPHRpVvTHhQ2Ndnpc3Yooadwn7as_M8UgvVIeWblVXmlA9g9daWTcFyXRqQleqTTUBiOfBcN8q06QxTHZB2jDWxryxkM1cXAD8LI-4G_H8a/w400-h300/IMG_6203.JPG" width="400" /></a></div></span><span style="font-family: arial; font-size: small;"> With those in place, </span><span style="font-family: arial; font-size: small;">the ventilators were screwed in place from underneath. </span></div><div style="text-align: left;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLu2jD1GwKlcObwS1BHDLK0rkBfy688WzX0DlhJauHqjzhMpO9eZSfDzHyqFyigakgXFF8ScmwCHCpb6Z9urCwPHp101ZiF7yP1oXMN-k0wsN1FvdmiebVbGhGbd9yIfnuRuzWpOXJuIr3XxcAtQAXJGs3wqf2s1WcblSfoZf4cK7Os5Y0kNYHbnAA/s4032/IMG_6305.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLu2jD1GwKlcObwS1BHDLK0rkBfy688WzX0DlhJauHqjzhMpO9eZSfDzHyqFyigakgXFF8ScmwCHCpb6Z9urCwPHp101ZiF7yP1oXMN-k0wsN1FvdmiebVbGhGbd9yIfnuRuzWpOXJuIr3XxcAtQAXJGs3wqf2s1WcblSfoZf4cK7Os5Y0kNYHbnAA/w400-h300/IMG_6305.JPG" width="400" /></a></div><span style="font-family: arial; font-size: small;">I
couldn't remember which way up the ratchet pieces were meant to go.
They affect how high (or alternatively - low) the lever will go. It
won't be until I fit the dashboard that I work that one out. However as
they are 'springloaded', I've discovereded that they can be carefully
pushed along the shaft and flipped over - so I can alter them later if I
need to.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuvYekA-Ys-qLpjVX2Xtfh-jmGq14C4LXhDKf6329xYhFTDDvl4GtKXrMv4oR0QwecnfDxr-f76rEVKcCUv4mhU0D4V2DJ3-AFsXGYnK7TqbS6fjVrS3HAQ7cZqsisoqVjFIymSpMRVk4uSgEjytIWUov8LKA_yZHAIY6EonX27ZzJ9i1e8FXsOllf/s4032/IMG_6298%20copy.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuvYekA-Ys-qLpjVX2Xtfh-jmGq14C4LXhDKf6329xYhFTDDvl4GtKXrMv4oR0QwecnfDxr-f76rEVKcCUv4mhU0D4V2DJ3-AFsXGYnK7TqbS6fjVrS3HAQ7cZqsisoqVjFIymSpMRVk4uSgEjytIWUov8LKA_yZHAIY6EonX27ZzJ9i1e8FXsOllf/w400-h300/IMG_6298%20copy.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">'Ratchets' on the lever shafts</span></td></tr></tbody></table><span style="font-family: arial; font-size: small;">When the dashboard is back in I can fit the decorative knobs on the ends of the levers. They are a push/ pull fit and you see cars with them missing. For that reason I took the opportunity to buy some spares that I came across. However I was surprised to find they didn't include the teeny tiny spring clips that actually hold them on the levers.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihbhCbVwpPhhaAIDt35Yfiir9xakFO8qaAmOOe81YMDyNrWmRxJ5a39qdXX-VBYvSluMrXfzghcQPI9DYv2cKth6yDO_QFRynY0R9X_jHFKGZNdKPP8DbOQweO3anywzSOD5LF2Z-aCGQQZctyQLgPF112Syi4ixgg1Kn0obKdilTOYmrj0pwv0qFU/s4032/IMG_7847.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihbhCbVwpPhhaAIDt35Yfiir9xakFO8qaAmOOe81YMDyNrWmRxJ5a39qdXX-VBYvSluMrXfzghcQPI9DYv2cKth6yDO_QFRynY0R9X_jHFKGZNdKPP8DbOQweO3anywzSOD5LF2Z-aCGQQZctyQLgPF112Syi4ixgg1Kn0obKdilTOYmrj0pwv0qFU/w400-h300/IMG_7847.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Spring clips and spare knobs</span><br /></td></tr></tbody></table><span style="font-size: small;"><span style="font-family: arial;">They are a very particular shape, but aren't listed as a seperate part. So if I do lose a knob, I guess 'll have to try and glue any replacement on. </span><br /></span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"></td></tr><tr><td class="tr-caption" style="text-align: center;"><br /></td></tr></tbody></table></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-73751730987661626002023-04-27T16:19:00.088+00:002024-02-14T22:16:47.420+00:00A Quick Word About.....The Mysteries Of The DS Wiper Motor.<div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Over the years I've seen lots of posts on Facebook and other forums about problems with DS wiper motors. Posts like this....</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0di93WaVQE5ZOLOKWLPMgoFld72qIIjwjhQ2gJeUGnbFNOygnhZyj2pXgDrZAivhnhqemrCjcpba0GGeSwjJXSDGOzine6N7O6xnM4y6s_3_NypZAGF4xh7bNzbuoogagPocYAALWjLczInhjybPUHPDxD2JCX-jnkwYXXYsWxNze0SEWNiB-4zoH/s923/1.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="415" data-original-width="923" height="288" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0di93WaVQE5ZOLOKWLPMgoFld72qIIjwjhQ2gJeUGnbFNOygnhZyj2pXgDrZAivhnhqemrCjcpba0GGeSwjJXSDGOzine6N7O6xnM4y6s_3_NypZAGF4xh7bNzbuoogagPocYAALWjLczInhjybPUHPDxD2JCX-jnkwYXXYsWxNze0SEWNiB-4zoH/w640-h288/1.jpeg" width="640" /></a></div><span style="font-family: arial;">And this...... </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg52Uda6zsEdu8YkeHPKPJqg6C6bzP8ZLpjHP3X6y_WlhJOlqwmYXgWO8PM3RPZIvv0lsRxFK34Gkr1nz41gHG7OJR0d49DaWLPKtJJF7k9o9AiDwZF_CvAT1jzCZ9l3SdLDfJ7ehysafnWo5x08xLudNfQhR8awhKxTUDChY_6P6nEr9fYpcPdedFq/s741/2.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="574" data-original-width="741" height="496" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg52Uda6zsEdu8YkeHPKPJqg6C6bzP8ZLpjHP3X6y_WlhJOlqwmYXgWO8PM3RPZIvv0lsRxFK34Gkr1nz41gHG7OJR0d49DaWLPKtJJF7k9o9AiDwZF_CvAT1jzCZ9l3SdLDfJ7ehysafnWo5x08xLudNfQhR8awhKxTUDChY_6P6nEr9fYpcPdedFq/w640-h496/2.jpeg" width="640" /></a></div>And this.....</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"></span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEim_iFNKSZpqptEyyOQONLgWi_ACYzVj-KC6-Q6tb580zWB_VMC9LJI4e0o9oS5Z5Cg6WUmWjivVbR-XXeiapsv7ixxJsDFex4_ITtNsOyARIdgeWE-ncINLSKqrZMuMpKRiYFebUV5uVJ82UyW3z_aDcN2eMv4YeMpf-LSibQKzJ79pcY3QrElr6CV/s743/4.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="698" data-original-width="743" height="602" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEim_iFNKSZpqptEyyOQONLgWi_ACYzVj-KC6-Q6tb580zWB_VMC9LJI4e0o9oS5Z5Cg6WUmWjivVbR-XXeiapsv7ixxJsDFex4_ITtNsOyARIdgeWE-ncINLSKqrZMuMpKRiYFebUV5uVJ82UyW3z_aDcN2eMv4YeMpf-LSibQKzJ79pcY3QrElr6CV/w640-h602/4.jpeg" width="640" /></a></div>This one (drawing power with motor off):</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQk836DFo3BY0cNUwutnq2dtLEmIbIo2W1Fi82X1xhcXbQWhvDPTzATKNf8RtaPdSGLrxgAVZbVhBL-FphMpYOnXFlYov6GN-boPVZ3cGFdt68FDEaT23A_N6VW2sk2SWemgOhzOBxom9gkDLjEzik0jOxVzWJ7I87T04c0oHqMDyLm8rBaQcQ9aW-/s1296/AF1.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="285" data-original-width="1296" height="140" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQk836DFo3BY0cNUwutnq2dtLEmIbIo2W1Fi82X1xhcXbQWhvDPTzATKNf8RtaPdSGLrxgAVZbVhBL-FphMpYOnXFlYov6GN-boPVZ3cGFdt68FDEaT23A_N6VW2sk2SWemgOhzOBxom9gkDLjEzik0jOxVzWJ7I87T04c0oHqMDyLm8rBaQcQ9aW-/w640-h140/AF1.jpeg" width="640" /></a></div></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">And how about this?<br /></span></span></div><span style="font-size: small;"><span style="font-family: arial;"></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"></span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDM15e0A7h-2qSmDiOzMaqZ3g7_egw_iEg18wgbEg4MTzgkvdcVDFTruOuDGKl4owFAykptiYb2bUTt76v_24CMeNdrHjKggpP68OnLzj3M-Gjgl8PI90kDG20s6LNCJODYwYYGz65NA1nSGhGqxUYXtDdpTijPLjjgzhIZlgExWtqJgLyYLQDKCLA/s742/3.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="704" data-original-width="742" height="608" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDM15e0A7h-2qSmDiOzMaqZ3g7_egw_iEg18wgbEg4MTzgkvdcVDFTruOuDGKl4owFAykptiYb2bUTt76v_24CMeNdrHjKggpP68OnLzj3M-Gjgl8PI90kDG20s6LNCJODYwYYGz65NA1nSGhGqxUYXtDdpTijPLjjgzhIZlgExWtqJgLyYLQDKCLA/w640-h608/3.jpeg" width="640" /></a></div></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">These examples relate to 1968 cars that have the same wiper motor, and wiper motor switch as my car. Heat seems to be a theme. Heat is bad. Especially if the motor is meant to be turned off because heat can cause a fire..... The other theme seems to be confusion over how to wire the wiper motor up - what connections go where. </span></span><span style="font-size: small;"><span style="font-family: arial;">And
why. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">A </span></span><span style="font-size: small;"><span style="font-family: arial;">wiring/ colour coding problem I discovered when I rebult my wiper motor reminded me of these other problems and I decided to get to the bottom of my wiper motor circuitry once and for all.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Just
to be clear, this is about a Bosch wiper motor from a mid/ late
1960s car, controlled by a knob on the dashboard. I don't know how much
of this will be relevant to later cars (October 1969 onwards) that have
the wipers controlled by a stalk on the dash. </span></span><span style="font-size: small;"><span style="font-family: arial;">The
two unit's are easy to distinguish. Later - post October 1969 - cars
have FOUR cables and solder points on the gear head.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeymxEB5rVmy6pBD0ktoLPEyV8hJ7qWXNc97Qdvhvc13-hVN2J4_P9vBGywvvSZjOF_Zh-hGUh5ZUrY2s3-UDxgEiT4GnpT2AkqjoenRiWOsLIYlAv8Ky_5J__HXwThjMDSiYIq3PO2_ATKJDETjcOSbDmtvpNbx-ugEwUjjyGl1fbMykMrBbgV9I7/s2016/Mathieu%20Dutre.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2016" data-original-width="1512" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeymxEB5rVmy6pBD0ktoLPEyV8hJ7qWXNc97Qdvhvc13-hVN2J4_P9vBGywvvSZjOF_Zh-hGUh5ZUrY2s3-UDxgEiT4GnpT2AkqjoenRiWOsLIYlAv8Ky_5J__HXwThjMDSiYIq3PO2_ATKJDETjcOSbDmtvpNbx-ugEwUjjyGl1fbMykMrBbgV9I7/w300-h400/Mathieu%20Dutre.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Later four wire motor (photo credit: Mathieu Dutre)</span><br /></td></tr></tbody></table>My car, with a
two-speed mechanism has THREE contact points and solder terminals.</span></span><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzpz38caYHYM0xuOQGb8VxVX01PkOHsZ2P7KorlxxvV6FmtFvvzsIVyXAPvZ9iNaIqL2zaVHZx7fIiXc1T_U0ZY2aOeTy4Y50FIXObTGO09L4lRj4MxP4XeB0Km176GOoUfBDeoLJ7Q1sQMevZaYrxmGfEYJlCrA5T29d5LpU1JqC1da_VztTOrKma/s3264/IMG_0526.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzpz38caYHYM0xuOQGb8VxVX01PkOHsZ2P7KorlxxvV6FmtFvvzsIVyXAPvZ9iNaIqL2zaVHZx7fIiXc1T_U0ZY2aOeTy4Y50FIXObTGO09L4lRj4MxP4XeB0Km176GOoUfBDeoLJ7Q1sQMevZaYrxmGfEYJlCrA5T29d5LpU1JqC1da_VztTOrKma/w300-h400/IMG_0526.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Two speed motor with three solder points</span><br /></td></tr></tbody></table> Cars from the early 60s had one speed motors with just TWO contact points.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdKrZQz7zv8h6qGhuLewCaRDoKjioXAxMoLYW1pMgGdZttsL09gXZQTWPqPrInv55B4g0KMFqi81Q8zkdM3vIpcstsUhq_F94AdKkWChbk6WHLU2uKBE01yi5hx0fPHk4TJqL8KbDfh3WJG5xK2JYeBpl6Jfv0f1HHOM6rJLw8ZlsZYTW9O4-7taQ6/s488/one%20speed_PaulE.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="413" data-original-width="488" height="339" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdKrZQz7zv8h6qGhuLewCaRDoKjioXAxMoLYW1pMgGdZttsL09gXZQTWPqPrInv55B4g0KMFqi81Q8zkdM3vIpcstsUhq_F94AdKkWChbk6WHLU2uKBE01yi5hx0fPHk4TJqL8KbDfh3WJG5xK2JYeBpl6Jfv0f1HHOM6rJLw8ZlsZYTW9O4-7taQ6/w400-h339/one%20speed_PaulE.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">One speed motor with two solder points (photo by PaulE)</span><br /></td></tr></tbody></table>These earlier one speed wipers were controlled by a simple 'pull/ push', 'on/ off' knob.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxkrGdtLOSz-t9KYyXms_72fOUgLwkkctbERyOmeKs9PlmjkwEzGG-w4pC5HVoH65yajuOx9LVND-dTrsGthXkwl93fQbJWdJ3uf9CPuykQqxuOq2UbbHYl_7ECkZZCh7Z0UviuMFZVSq7mx878i7XKe7k_UqeHNzpJvdv_LfmlffxHj7TlsU5Fngg/s3938/Dash%20switch_1967.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2801" data-original-width="3938" height="285" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxkrGdtLOSz-t9KYyXms_72fOUgLwkkctbERyOmeKs9PlmjkwEzGG-w4pC5HVoH65yajuOx9LVND-dTrsGthXkwl93fQbJWdJ3uf9CPuykQqxuOq2UbbHYl_7ECkZZCh7Z0UviuMFZVSq7mx878i7XKe7k_UqeHNzpJvdv_LfmlffxHj7TlsU5Fngg/w400-h285/Dash%20switch_1967.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Pull/ push wiper switch for one speed wipers</span><br /></td></tr></tbody></table></span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">When
the two speed wipers (like mine) were introduced, the knob looked
similar, but rotated between 'off' slow' and 'fast'. The head of the
knob has an arrow on it so you can tell what speed position its in. This photo shows 'off'.<br /></span></span></div></div><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhhRMaot5Wpwmi7XmnqeE54jTHlFkbmsFXMPCibwfgDEI-KvGuLfBqT5owawaoDSYYuZ8nDO2pD7KsSoz1AP-iGXyySMpXYY81ekcu60giQUR-aMZIO_PABqcnbk71QGS5DMrLOiIgD7XNifbQ-4DCcNGVTpYooI5WcbqglKyDm2Ln6yZ4JgJnf-qJ/s3909/Dash%20switch_1968_b.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2940" data-original-width="3909" height="301" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhhRMaot5Wpwmi7XmnqeE54jTHlFkbmsFXMPCibwfgDEI-KvGuLfBqT5owawaoDSYYuZ8nDO2pD7KsSoz1AP-iGXyySMpXYY81ekcu60giQUR-aMZIO_PABqcnbk71QGS5DMrLOiIgD7XNifbQ-4DCcNGVTpYooI5WcbqglKyDm2Ln6yZ4JgJnf-qJ/w400-h301/Dash%20switch_1968_b.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Twisting switch for two speed wipers - note arrow</span><br /></td></tr></tbody></table></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I recently dismantled and rebuilt my wiper motor and studied how it was wired. You can read about that <a href="http://ds-restoration.blogspot.com/2023/04/windscreen-wiper-motor-strip-down-and.html" target="_blank">HERE</a>. I'm going to walk through all the components and connections. Then I'm going to propose some wiring diagrams showing how the circuits fit together. Then - based on that - I'm going to describe how it seems to work.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><b>Power supply to the Switch and Wiper Motor</b></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">From the battery, the 12V supply goes into the loom and emerges at a fuse (the yellow colour-coded fuse) - which just happens to be over by the wiper motor.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfAl27P6hbsDYrAJkLjVX7caR8s2In4efkZ85FdA4rTWJykqylclrX7hG1RdLhsgcuJk0Wx0qGZTMMN2fxJsIQlLrXqSKutodzlxacBn84w4aPs2DPdRMU2aADLmAxGpJiq4Khi5EbM2cgrNFSBF3lIqbjHmQ9o85lllTLDkY5CJhyDdjqF51s2Tkf/s4032/IMG_8005.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfAl27P6hbsDYrAJkLjVX7caR8s2In4efkZ85FdA4rTWJykqylclrX7hG1RdLhsgcuJk0Wx0qGZTMMN2fxJsIQlLrXqSKutodzlxacBn84w4aPs2DPdRMU2aADLmAxGpJiq4Khi5EbM2cgrNFSBF3lIqbjHmQ9o85lllTLDkY5CJhyDdjqF51s2Tkf/w300-h400/IMG_8005.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Fuse box under the wiper motor</span><br /></td></tr></tbody></table>From there, the supply goes back into the loom and splits into two feeds. Once feed goes to the wiper switch on the dashboard.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">It's worth pointing out that there is another similar arrow-headed switch on the
dashboard - the switch for the parking lights (off, right and left). If you are groping around with wiring behind a part-dismantled dash, it's easy to get these
muddled. The wiper motor switch has THREE pins on the back.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgx2zR4YTwgVK5MsLB8qYzPJ3ED4-jY7t2KZ4bxonjWY47YBjxFYddDp1vjN8wgwD74g_XA0wlDQWX1kbQu_y8CCOpBi17vSs2EZbVyuw-bNUxpQFAWHF8BdwFip1_R9ip39rSGg1kMCLghVJykTsC-d0rC9DykFp7kXw55GYbL4tWFUnBW5tKnxhdX/s4032/IMG_5896%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgx2zR4YTwgVK5MsLB8qYzPJ3ED4-jY7t2KZ4bxonjWY47YBjxFYddDp1vjN8wgwD74g_XA0wlDQWX1kbQu_y8CCOpBi17vSs2EZbVyuw-bNUxpQFAWHF8BdwFip1_R9ip39rSGg1kMCLghVJykTsC-d0rC9DykFp7kXw55GYbL4tWFUnBW5tKnxhdX/w400-h300/IMG_5896%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Wiper switch has THREE pins</span><br /></td></tr></tbody></table>The power from the loom connects to the green colour coded terminal of the wiper switch. That is power 'in' to the switch. </span></span><br /><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHQHAXJoMDQM1hAXWJkhLGNRNMraKZmvkoU0LoY0u8bUiPu4yEDOYZ-SZ5n_OKRZ9_xJgaONPxrMW64anmSby4F-S1i-uUOEFcoqur1aMMAYbZDxfbglv2KkDeGGZ_oIQjgu8N3Xm1w3pvCPtVhn8W3vrA7aN1gloQve6JoFwMQ49jrbao5_KWyJ_n/s4032/IMG_8007.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHQHAXJoMDQM1hAXWJkhLGNRNMraKZmvkoU0LoY0u8bUiPu4yEDOYZ-SZ5n_OKRZ9_xJgaONPxrMW64anmSby4F-S1i-uUOEFcoqur1aMMAYbZDxfbglv2KkDeGGZ_oIQjgu8N3Xm1w3pvCPtVhn8W3vrA7aN1gloQve6JoFwMQ49jrbao5_KWyJ_n/w400-h300/IMG_8007.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">'Green' is power in to the switch</span><br /></td></tr></tbody></table></span></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">T</span></span><span style="font-size: small;"><span style="font-family: arial;">he other two terminals (red and blue) are power out of the switch.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWVvzyEOaAgD4NzJJlzuGtWVsnEvMQRvsXUbl7Bwomd0n65D_gwbl-34siTI4WfjHOwfKp45LSOEKwccLz2xt7LPS_qsS4EMxG2VlO6tyM1_wPgFNpBp0igCKirVLAsdQpT7YH0CQI-cKqSxBQTiVAhLOw9xy7niDsZuRpD8LfHQBildpC1nY4fmqr/s4032/IMG_8008.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWVvzyEOaAgD4NzJJlzuGtWVsnEvMQRvsXUbl7Bwomd0n65D_gwbl-34siTI4WfjHOwfKp45LSOEKwccLz2xt7LPS_qsS4EMxG2VlO6tyM1_wPgFNpBp0igCKirVLAsdQpT7YH0CQI-cKqSxBQTiVAhLOw9xy7niDsZuRpD8LfHQBildpC1nY4fmqr/w400-h300/IMG_8008.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">'Red' and 'blue' are power from the switch to the wiper motor</span><br /></td></tr></tbody></table>The wires that connect to red and blue go back in to the loom and emerge </span></span><span style="font-size: small;"><span style="font-family: arial;">in the engine bay at the motor and still have red and blue tags. The other branch of supply from the fuse goes directly to the wiper motor area as the black tagged contact.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBVnQKur9NO6X0c2Y6rG61N_J_c_-RA-3nVmWIjbiCQyTWN5O2dND8AhN__xs7MySrV5JvoZPnGQH5nZ1qVM-Tx62wPrLkvK4TWtZV6f6TL4F8u-CWbiCld62w4C027ASJuMEFrQ5W2swc1NaCnNWDcHoa-_VRVaP4oHBmNYCPwDOsweOxnAr2-8wZ/s4032/IMG_8010.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBVnQKur9NO6X0c2Y6rG61N_J_c_-RA-3nVmWIjbiCQyTWN5O2dND8AhN__xs7MySrV5JvoZPnGQH5nZ1qVM-Tx62wPrLkvK4TWtZV6f6TL4F8u-CWbiCld62w4C027ASJuMEFrQ5W2swc1NaCnNWDcHoa-_VRVaP4oHBmNYCPwDOsweOxnAr2-8wZ/w400-h300/IMG_8010.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The three wiper motor connections coming from the loom</span><br /></td></tr></tbody></table>All three of these wires are for carrying supply to the wiper motor. Remember that the black-tagged supply does not pass through the wiper switch or the cars ignition switch. Other than the fuse blowing - It's <u>permanently live</u>.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">So what you find coming from your loom at your wiper motor is:</span></span></div><ul style="text-align: left;"><li style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">a black tagged wire (permanent live feed)</span></span></li><li style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">a blue tagged wire (switched feed from the dashboard switch)</span></span></li><li style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">a red tagged wire (switched feed from the dashboard switch) <br /></span></span></li></ul><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span><span style="font-size: small;"><span style="font-family: arial;"><b>External wiper motor connections</b></span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">On the alloy gear housing of the motor is a cream or off white platic insulating strip with three solder connections points. </span></span><span style="font-size: small;"><span style="font-family: arial;">The
alloy gear housing also has an 'eye' hole through which these three
wires pass. It's just a cable tidy really but serves as a useful
reference point. </span></span><span style="font-size: small;"><span style="font-family: arial;">I'm going to call the solder point <u>furthest</u>
from the eye 'solder point A'. I'm going to call the middle solder point
'solder point B' and the solder point nearest to the
eye..............'solder point C'.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCfo-Iddnf5SVPB-FYHnY5xJ7i46ScJxS0GFwBvLcgogueIdEnaa05ozpcjOIw0E4PCqZvkY9zOJOHwRp1XJDuPb2sXTmuhRJ5DsJ4PUBzGKjECF8tjfql8hP4elzloh5oiD4LdYDKHn1O-1_DDa0gBCVxkSkajvnW1kwd9LlMzdPGyRXK41UZZLk-/s2784/IMG_8012%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1838" data-original-width="2784" height="264" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCfo-Iddnf5SVPB-FYHnY5xJ7i46ScJxS0GFwBvLcgogueIdEnaa05ozpcjOIw0E4PCqZvkY9zOJOHwRp1XJDuPb2sXTmuhRJ5DsJ4PUBzGKjECF8tjfql8hP4elzloh5oiD4LdYDKHn1O-1_DDa0gBCVxkSkajvnW1kwd9LlMzdPGyRXK41UZZLk-/w400-h264/IMG_8012%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Arbitrary labelling of the solder points</span><br /></td></tr></tbody></table>Each of these solder points has a short colour-coded wire with a male bullet connector on it.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQzrS2or3g4Hxq2IGTMbl_LtoFFFVPOULpm75v41nJpJXhVJp_Tjq9IG42wYTaBUS7KW0_7Zj37SkLUanOtoXQL1QH-HgNNBwSV9kcRFGr12NQZ85KpnzYs0cAsHQYnnGApdPIaSlZ9SOQqPvJI55jMitUEXGLbnWq1I0PrjXHE2iNdRSPIOK1T5yz/s4032/IMG_8011.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQzrS2or3g4Hxq2IGTMbl_LtoFFFVPOULpm75v41nJpJXhVJp_Tjq9IG42wYTaBUS7KW0_7Zj37SkLUanOtoXQL1QH-HgNNBwSV9kcRFGr12NQZ85KpnzYs0cAsHQYnnGApdPIaSlZ9SOQqPvJI55jMitUEXGLbnWq1I0PrjXHE2iNdRSPIOK1T5yz/w400-h300/IMG_8011.JPG" width="400" /></a></div></span></span><span style="font-size: small;"><span style="font-family: arial;">These connect to the three equivalent coloured wires on coming out of the loom.<br /></span></span><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifhMRBoJbmFt_uq1hIVHpxsZB0F8QBXL8F55H-DsVeTzn_eHp7-1Sbrfi01HXQRi0OxuHBOUVpT8Ct3tSqkwAbDMdglzIZzw3KYVYEZH-_7plZFMgmttgawL6Ef33G_NE8exzDS3HIrtdfRsTDoFTvSBYZuf7uw_uhmlgON5yBfZzTZsNZ1rWf63B2/s4032/IMG_8009.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifhMRBoJbmFt_uq1hIVHpxsZB0F8QBXL8F55H-DsVeTzn_eHp7-1Sbrfi01HXQRi0OxuHBOUVpT8Ct3tSqkwAbDMdglzIZzw3KYVYEZH-_7plZFMgmttgawL6Ef33G_NE8exzDS3HIrtdfRsTDoFTvSBYZuf7uw_uhmlgON5yBfZzTZsNZ1rWf63B2/w400-h300/IMG_8009.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;"><span style="font-family: arial;">Three power supplies to the wiper motor</span></span></td></tr></tbody></table></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Two wires emerge from a hole in the gear housing near where it joins the main motor body.<br /></span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnbOkUKG0i5-HjnYrTgHiL3sVa1A_TPPeEnn75Wcr0w5wL8WIHaQQT6Stcivw0XVV_tCaf15rJaQ03rg0FJseSTEwKvwMhOQhuHWUkqYJI3ZgyIhn8DwgVtfLzIR5PoKZRwaMX-GAO_Fv5waocFaGn7eKOQlccy5gvR-tpqG3LOsM0OjEzInVl4cvL/s4032/IMG_8015.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnbOkUKG0i5-HjnYrTgHiL3sVa1A_TPPeEnn75Wcr0w5wL8WIHaQQT6Stcivw0XVV_tCaf15rJaQ03rg0FJseSTEwKvwMhOQhuHWUkqYJI3ZgyIhn8DwgVtfLzIR5PoKZRwaMX-GAO_Fv5waocFaGn7eKOQlccy5gvR-tpqG3LOsM0OjEzInVl4cvL/w400-h300/IMG_8015.JPG" width="400" /></a></div><span style="font-family: arial;">There is a thick wire in a brown woven sleeve. This also joins to solder point B - the middle solder point.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBH3Rx39imFc3Cb9n8zhXCRaYzj3sSTnpSiFmdh849Uh-_oi3tBUQE5bG46ih36mvP6VPgdyKqIENQ0PQ0phrWeXYpl44rYCeKNtLYTWKr282Sii4LjutxxhAa0p3OYxAdYkDiGNBkV2Hcjf66JMfEm72zW9bP4y-L2MMFjDFgrcbjCDR0eK1GO65q/s2033/IMG_8019%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1352" data-original-width="2033" height="266" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBH3Rx39imFc3Cb9n8zhXCRaYzj3sSTnpSiFmdh849Uh-_oi3tBUQE5bG46ih36mvP6VPgdyKqIENQ0PQ0phrWeXYpl44rYCeKNtLYTWKr282Sii4LjutxxhAa0p3OYxAdYkDiGNBkV2Hcjf66JMfEm72zW9bP4y-L2MMFjDFgrcbjCDR0eK1GO65q/w400-h266/IMG_8019%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Note that the brown sleeved wire is a thick wire</span><br /></td></tr></tbody></table></span></span><span style="font-size: small;"><span style="font-family: arial;">The other wire is a thin wire in a white plastic sleeve. This joins to soder point A - the one furthest from the eye hole.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4nbgjfNm5DmyM8YgFVjdjmFJBZ_srjB8YV6l6KK876-bMIoJY0D_aa9LteJNgAMtWTuHs8e-Kd6_GSc4TjH47nJj-xtoVGfP86f8TNTvgTttUH5IrKXuMuX0UDrewbhl2SfBkc86TsUUKAMHFH6rAPrcw0Hq2fpOgoEVq6vs2NLzgD5w-8vt7SJM3/s1880/IMG_8020%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1153" data-original-width="1880" height="245" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4nbgjfNm5DmyM8YgFVjdjmFJBZ_srjB8YV6l6KK876-bMIoJY0D_aa9LteJNgAMtWTuHs8e-Kd6_GSc4TjH47nJj-xtoVGfP86f8TNTvgTttUH5IrKXuMuX0UDrewbhl2SfBkc86TsUUKAMHFH6rAPrcw0Hq2fpOgoEVq6vs2NLzgD5w-8vt7SJM3/w400-h245/IMG_8020%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Note that the white sleeved wire is a thin wire</span><br /></td></tr></tbody></table><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><b>Inside the Gear Casing<br /></b></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">With the motor taken apart we can see what is going on on the other side of that cream plastic insulating strip. Solder points 'B' and 'C' have two contacts that extend into the casing body. The end of solder point 'A' is just bent over to secure it within the cream plastic strip.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrSlda1muQ8cSCojpvsOzPm8JsAjYs5PiDIpTi1dB0mHPyoF_Rz4q5gKaty3ZJuLuEI4nxEXKbHVhSFSYOacRGkjISsVZHG8f-PbM_nai-VQSrLoiVoeEAt7P_WwQlawIAcLhHJsKUfXsRu_OVzmZsSyrcVGDzkTjS_Piqd5BJGAHnN9CW_bAmUuBy/s2436/IMG_7935%201%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1537" data-original-width="2436" height="253" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrSlda1muQ8cSCojpvsOzPm8JsAjYs5PiDIpTi1dB0mHPyoF_Rz4q5gKaty3ZJuLuEI4nxEXKbHVhSFSYOacRGkjISsVZHG8f-PbM_nai-VQSrLoiVoeEAt7P_WwQlawIAcLhHJsKUfXsRu_OVzmZsSyrcVGDzkTjS_Piqd5BJGAHnN9CW_bAmUuBy/w400-h253/IMG_7935%201%20copy.jpg" width="400" /></a></div><span style="font-family: arial;">The wiper motor gear wheel is within the gear casing lid. It's made of nylon or some similar material, but has a conductive metal disc on it's surface. When the gear casing lid is fitted, the two contacts described above both contact the metal disk as the gear wheel rotates. </span></span><span style="font-size: small;"><span style="font-family: arial;">Note that the disc has a segment cut out around it's outer circumference. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWhwWLkBLehJXblRlle4RrjB2hlX8r6fBv1A2xpdzsbJKP8sETUY7wxmdWWFYzeKy-ERmvY9_OPp3KrhhZ967_eJr9-TDax2S6ESDcIUKZGJ3X_X7NElaeuLOZOCOdv4WSwKL0LBNdf_fZAsVmSJ-9K2Auzt8YhV3953QF0H8D3CcuBtm-ibu7KoB0/s4032/IMG_7935%202.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWhwWLkBLehJXblRlle4RrjB2hlX8r6fBv1A2xpdzsbJKP8sETUY7wxmdWWFYzeKy-ERmvY9_OPp3KrhhZ967_eJr9-TDax2S6ESDcIUKZGJ3X_X7NElaeuLOZOCOdv4WSwKL0LBNdf_fZAsVmSJ-9K2Auzt8YhV3953QF0H8D3CcuBtm-ibu7KoB0/w400-h300/IMG_7935%202.jpg" width="400" /></a></div><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><b>Wiper Motor Body - Internal connections</b></span></span></div><div style="text-align: justify;"><span style="font-size: small;"></span></div><div style="text-align: justify;"><span style="font-size: small;"></span></div><div style="text-align: justify;"><span style="font-size: small;"></span></div><div style="text-align: justify;"><span style="font-size: small;"></span></div><div style="text-align: justify;"><span style="font-size: small;"></span></div><div style="text-align: justify;"><span style="font-size: small;"></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I'm now going to follow the two wires from the outside of the cream plastic insulating strip </span></span><span style="font-size: small;"><span style="font-family: arial;">back into the motor itself.<br /></span></span><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwIryGjKF6Z-7HNOXsOfEAowtijxAMwrkAvVB3pwBnNl21h6jgYw2-QuUB88kiZjTA-9H25fpUYZI_JL8DdIHfSurrQfhKRVyH5af_HpoQpY4uJNLFZDRvZTCKTIuxE32W7FrIbc85s1o4gpcq1EFAbELwXDBADfBUpTRgSHuokk2KSeAneDWl4OVK/s4032/IMG_7926%20copy.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwIryGjKF6Z-7HNOXsOfEAowtijxAMwrkAvVB3pwBnNl21h6jgYw2-QuUB88kiZjTA-9H25fpUYZI_JL8DdIHfSurrQfhKRVyH5af_HpoQpY4uJNLFZDRvZTCKTIuxE32W7FrIbc85s1o4gpcq1EFAbELwXDBADfBUpTRgSHuokk2KSeAneDWl4OVK/w400-h300/IMG_7926%20copy.JPG" width="400" /></a></div><span style="font-family: arial;">The thick wire in the brown woven sleeve is one end of a 'stator' winding fixed to the inside of the motor body.</span></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The thin wire in the white plastic sleeve</span></span><span style="font-size: small;"><span style="font-family: arial;"> also goes
to the <u>same</u> 'stator' winding core </span></span><span style="font-size: small;"><span style="font-family: arial;">(arrowed) - </span></span><span style="font-size: small;"><span style="font-family: arial;">fixed to the inside of the motor
body</span></span><span style="font-size: small;"><span style="font-family: arial;">. </span></span></div><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNtrwoEmlfM7yfGlPCEYoH2fbD3cmJ13o5QMsiFmDAdaq1fyjbPr-Uiuuy_Nie7TvNa4Rp6I_-rThPmTSKAtsNyr_GDZ4d-IUKoAuxzZIjHdZBuKzKk09xqbBEAh9AbhRWQxoQerGOhYCZdkAktUiNy7vWa730uP0ZTr7zuoS74MH5QdmP-RtKVKFb/s4032/IMG_7927%20copy%202.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNtrwoEmlfM7yfGlPCEYoH2fbD3cmJ13o5QMsiFmDAdaq1fyjbPr-Uiuuy_Nie7TvNa4Rp6I_-rThPmTSKAtsNyr_GDZ4d-IUKoAuxzZIjHdZBuKzKk09xqbBEAh9AbhRWQxoQerGOhYCZdkAktUiNy7vWa730uP0ZTr7zuoS74MH5QdmP-RtKVKFb/w300-h400/IMG_7927%20copy%202.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">The two wires are wound around the same core</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">Crucially, and although this winding is part of the same overall winding as that
of the thick wire </span></span><span style="font-size: small;"><span style="font-family: arial;"> </span></span><span style="font-size: small;"><span style="font-family: arial;">- the two are insulated from each other.</span></span><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">In this next photo of the other end of the motor body, you can clearly see how these two (thick and thin) wires come from the same core.</span></span><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_PLk5bXMlMjOJt1e1vtbS-4Q9fK7Dvu7HswMf_PdxQpmZwIUjb5b_je4BSzC7NLHdC3vV_PLW0WtoGmuSL4l0McLYt_VFzhHBWh1SnYZ3lRUT9423RP9Fxs5ecLAYAe99Y9pRQN2WJk5PYhfVII-0BtO7b7s7gpSwkOSrfH7cSrJ5T2r00i91NBzh/s4032/IMG_7933%20copy.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_PLk5bXMlMjOJt1e1vtbS-4Q9fK7Dvu7HswMf_PdxQpmZwIUjb5b_je4BSzC7NLHdC3vV_PLW0WtoGmuSL4l0McLYt_VFzhHBWh1SnYZ3lRUT9423RP9Fxs5ecLAYAe99Y9pRQN2WJk5PYhfVII-0BtO7b7s7gpSwkOSrfH7cSrJ5T2r00i91NBzh/s320/IMG_7933%20copy.JPG" width="320" /></a></div><span style="font-family: arial;">The other end of the thick wire goes to one of the armature brushes at the other end of the motor body. I'm going to call this 'brush 1'.</span></span></div></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbpFvQI2ZpAbEPcvSrt3HHjXGBZfHmY3pojCy19kOthFfo-DoASN43H9Ca-qKtB0FfnGbdZaVNsFLgrFBTR-SrgYTa0tWGCqg7Ay1vG3qjFAPgeymrhaai1lJdl7gc-c8EdySKxJpXd7MXErdKqpMkcGWMykSepkn2BouoOTxMyEZg3hA1kKo3WZ2k/s4032/IMG_7931%20copy%202.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbpFvQI2ZpAbEPcvSrt3HHjXGBZfHmY3pojCy19kOthFfo-DoASN43H9Ca-qKtB0FfnGbdZaVNsFLgrFBTR-SrgYTa0tWGCqg7Ay1vG3qjFAPgeymrhaai1lJdl7gc-c8EdySKxJpXd7MXErdKqpMkcGWMykSepkn2BouoOTxMyEZg3hA1kKo3WZ2k/w400-h300/IMG_7931%20copy%202.jpg" width="400" /></a></div><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The other end of the thin wire goes to the other brush. Yep: 'brush 2'.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDnnWUp27qAMB8uzwIRcsF-HFAQEhq2cW9dlqIJBwMQ6rmuSxyRHSQvdVzUSAOQEwYg3Lag_66yleL4hTcoXOYS_8rq7nzhPauWd6BqfOdCt97UW1APSNjHyCYbJ_E6ECOmXv9jCxOwXCpY-OTDqo7aNPu5VcYQX7rHkF56VaVDSPslHTz7wEb-Ao3/s4032/IMG_7932%20copy%202.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDnnWUp27qAMB8uzwIRcsF-HFAQEhq2cW9dlqIJBwMQ6rmuSxyRHSQvdVzUSAOQEwYg3Lag_66yleL4hTcoXOYS_8rq7nzhPauWd6BqfOdCt97UW1APSNjHyCYbJ_E6ECOmXv9jCxOwXCpY-OTDqo7aNPu5VcYQX7rHkF56VaVDSPslHTz7wEb-Ao3/w400-h300/IMG_7932%20copy%202.jpg" width="400" /></a></div><span style="font-family: arial;">As you might expect for a motor, there is another stator winding opposite the one(s) just described above. This is made of thick wire. At the gear casing end of the motor body, one bare end of the wire is fixed to the steel casing somehow - possibly soldered? <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl4B2hVF-E0OTvw2ZKkHh38iCerwARo2lSxyxpDhlTET4t2xDGWVBYgdsKwdJXw7ecSAlRQaw7d9x1c108Qu3OYeqzOJVS0Xj_EFlaJzRajqdZ06oUJswGwGEApk_AWCP0L9rDGUKwqjkV1LTDGuPkY1vlHQXYfOUSERUBgtVaetD3NSMTT2xuWstN/s4032/IMG_7929%20copy.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl4B2hVF-E0OTvw2ZKkHh38iCerwARo2lSxyxpDhlTET4t2xDGWVBYgdsKwdJXw7ecSAlRQaw7d9x1c108Qu3OYeqzOJVS0Xj_EFlaJzRajqdZ06oUJswGwGEApk_AWCP0L9rDGUKwqjkV1LTDGuPkY1vlHQXYfOUSERUBgtVaetD3NSMTT2xuWstN/w300-h400/IMG_7929%20copy.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">One end is fixed to the casing</span><br /></td></tr></tbody></table></span></span><span style="font-family: arial; font-size: small;">The other end of this winding joins 'brush 2' along with the thin wire.</span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAxaKuyaUoTvltSM-8neVORRJsfSOUhmKQFq6vbNpMB5GKrovMeXLL64I_aSZjlhxhsgyfk683tBj5zSy71rxpvH4Zf3Q8svPbObptCCMGc2Dfd0We20hGAe6olgYa6dZv2uiajLIUJUKU5g8i9irhFsXJoANs305esx9jRmIdg9xSMdvLZ5AUo3wC/s4032/IMG_7931%20copy%203.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAxaKuyaUoTvltSM-8neVORRJsfSOUhmKQFq6vbNpMB5GKrovMeXLL64I_aSZjlhxhsgyfk683tBj5zSy71rxpvH4Zf3Q8svPbObptCCMGc2Dfd0We20hGAe6olgYa6dZv2uiajLIUJUKU5g8i9irhFsXJoANs305esx9jRmIdg9xSMdvLZ5AUo3wC/w400-h300/IMG_7931%20copy%203.jpg" width="400" /></a></div></span></span><span style="font-family: arial; font-size: small;"><span>That's just about it: all the wires and their end points are accounted-for. Having described the connectons on the motor brushes, I'm not going to bother describing the armature - the part that turns - as it can't really be fitted or connected wrongly.</span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span> </span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span>So what's going on? How does the wiper motor actually work? </span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><b>Circuit Diagram(s)</b></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span>This is the diagram for a mid/ late 1960s two speed wiper motor found in the repair manuals. </span></span><span style="font-size: small;"><span style="font-family: arial;">The Citroen workshop manuals show how the motors are wired into
the cars loom, but don't show the detail of connections inside the
switch and wiring inside ther wiper motor. </span></span></div><div style="text-align: left;"><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkiZOux74S546y3pzh9ZGd7wrRVYxt-kIFm6CgamETe1bsd4EqTleLUu5vyO5vLRT_SDL2sHr3E-_rk0fx9agk46Hfezsms-2-2Yqq58wwtw7_7schso52zO3zUZeA9jJ_9Ih_tt39N6ISwovfKqt-5nsxtO1tXFrCSap6ZT5B7nUyZg86BHLOULod/s1079/r.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="424" data-original-width="1079" height="253" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkiZOux74S546y3pzh9ZGd7wrRVYxt-kIFm6CgamETe1bsd4EqTleLUu5vyO5vLRT_SDL2sHr3E-_rk0fx9agk46Hfezsms-2-2Yqq58wwtw7_7schso52zO3zUZeA9jJ_9Ih_tt39N6ISwovfKqt-5nsxtO1tXFrCSap6ZT5B7nUyZg86BHLOULod/w640-h253/r.jpeg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;"><span style="font-family: arial;">Note connections 'Bl10' and 'R11' on the wiper switch (30) </span><br /></span></td></tr></tbody></table></div><div style="text-align: justify;"></div><div style="text-align: justify;"></div><div style="text-align: justify;"></div><div style="text-align: justify;"></div><div style="text-align: justify;"></div><div style="text-align: justify;"><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"> In fact even what the manuals
do show can include errors with colour coding...</span></span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyhyphenhyphenmNsQXT2pbX_9pNCM6zgPaNmBT8WfM-b01lWe0ac64iXjmn_yOBv-htredP2bOppAZrfIHkeofxK2MHgSVz6aYRGOiseHCmixxJkBDwx2D2RkgPelVmbCN89ttdlWImDocxB693ytae24A4_hzEFO6hoiJielmIseeQ1TL1sd-0dSE7I-1N3VY9/s1035/Bl.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="474" data-original-width="1035" height="294" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyhyphenhyphenmNsQXT2pbX_9pNCM6zgPaNmBT8WfM-b01lWe0ac64iXjmn_yOBv-htredP2bOppAZrfIHkeofxK2MHgSVz6aYRGOiseHCmixxJkBDwx2D2RkgPelVmbCN89ttdlWImDocxB693ytae24A4_hzEFO6hoiJielmIseeQ1TL1sd-0dSE7I-1N3VY9/w640-h294/Bl.jpeg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Incorrect: note how 'R11' at the wiper switch (42) has become 'Bl11'........</span><br /></td></tr></tbody></table><span style="font-family: arial; font-size: small;"><span>There is a variant diagram as, for a few short months Citroen briefly fitted an additional flying earth lead to the outside of the casing but in all other respects the circuits are the same.</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTXFOkGVCULOMMoe9VPRhe2y51fRoRRb_Idc2-5a82MEzQrN3tAMj7eALbpqumEJmhAUGgTG_iFxhcbS69Tk6unLsR_8bxAloxfLVuAfg0PFi3TVkaou_Rysm0mqK-62QHyTomtlTRJ6hk3JxcK3nxmh74dWX_6pnUpgipXIwE_QalKJYxwlQL_Efq/s609/earth%20lead%2049.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="399" data-original-width="609" height="263" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTXFOkGVCULOMMoe9VPRhe2y51fRoRRb_Idc2-5a82MEzQrN3tAMj7eALbpqumEJmhAUGgTG_iFxhcbS69Tk6unLsR_8bxAloxfLVuAfg0PFi3TVkaou_Rysm0mqK-62QHyTomtlTRJ6hk3JxcK3nxmh74dWX_6pnUpgipXIwE_QalKJYxwlQL_Efq/w400-h263/earth%20lead%2049.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Short-lived additional flying earth lead (49)</span><br /></td></tr></tbody></table>Someone also posted another snippet of a circuit diagram relevant to 1967/68 wiper motors, but I don't where it originated.</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_hWMb-VLIW5WWTZXZxVyXRzRV5DXDqw1hDnWT4HRMkZtay_widp6p93ZQ3Ll5WfpoVotAljKZfcmYm7IsPQMempXshGC2hgv2nPQkOqFccK-SkZzqrccPo3VMgTt1ju6iBWA9FmN8M-cE_HE7hWlYGazmcq6l-lQhHEmfAZrVDTBax_0Q67UqM023/s792/Wipers_67_68%20wiring%20diagram.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="792" data-original-width="473" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_hWMb-VLIW5WWTZXZxVyXRzRV5DXDqw1hDnWT4HRMkZtay_widp6p93ZQ3Ll5WfpoVotAljKZfcmYm7IsPQMempXshGC2hgv2nPQkOqFccK-SkZzqrccPo3VMgTt1ju6iBWA9FmN8M-cE_HE7hWlYGazmcq6l-lQhHEmfAZrVDTBax_0Q67UqM023/w382-h640/Wipers_67_68%20wiring%20diagram.jpeg" width="382" /></a></div></span><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>These kinds of diagrams are helpful for showing connections of the loom, but don't explain how/ why the wiper motor works. To me, the most useful thing about the diagram above is that it shows that it's the 'Bl' (blue) wire that is part of the 'park' mechanism - rather than the 'R' (red) wire. That narrows it down a bit!</span></span><br /></div></div></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> <br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>B</span></span><span style="font-family: arial; font-size: small;"><span>ased on my photos and the wiring described above, I produced my own circuit diagrams and I'll tell you how I think it operates. I'm not an auto-electrician and these diagrams are intended to show the 'active circuits' - the circuits doing the work in the given scenarios. I have greyed-out wires and connections not playing a key role. the diagrams are about current flow - and so motor operation - though this is not to say that electical testing will not show continuity between some points.<br /></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span> </span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><b>Basic Wiring Diagram <br /></b></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span>This is the 'basic' diagram that shows all of the wiring.</span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhikHE6InpCB1uYhRqEfEfQgl4JLWqa6oTMC5O7X0px3hd63ulCPPEQ9X73EkrmVn6vout1Z6V27CFbBRl-sqEY8VPCI9t4a6hHpHGskth36mibsdiV9un37H-3oLoSKYFjeQp1dNck9euNTZc03JwUmYXUpg7Ms8Zr3MSwP7sgbjj-l9J5Ux5RBBqb/s3507/motor%20wiring_full%20diagram%20copy%202.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2480" data-original-width="3507" height="453" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhikHE6InpCB1uYhRqEfEfQgl4JLWqa6oTMC5O7X0px3hd63ulCPPEQ9X73EkrmVn6vout1Z6V27CFbBRl-sqEY8VPCI9t4a6hHpHGskth36mibsdiV9un37H-3oLoSKYFjeQp1dNck9euNTZc03JwUmYXUpg7Ms8Zr3MSwP7sgbjj-l9J5Ux5RBBqb/w640-h453/motor%20wiring_full%20diagram%20copy%202.jpg" width="640" /></a></div></span></span><span style="font-size: small;"><span style="font-family: arial;">Note how the thick wire coil coming from solder point 'B' goes from 'Brush 1' and through the armature to reach 'Brush 2' and the second, thick-wound coil. Note how the thin wire coil bypasses 'Brush 1'. </span></span><br /><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><span><b> </b></span></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><b>Slow speed - first knob position</b><br /><span>In 'slow' mode, the contacts inside the switch provide power to <u>both</u> the red and blue contacts and so both the red and blue inputs to the wiper motor. Power goes into the motor directly via the wires connected to the solder points (points 'A' and 'B'). The sweeper brushes on the gear inside the gear case play no role.</span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrvePA8rW5dWS1alBB8-VILRRs8AGExwkdmCtqQv8gTVbyaUzOqVejqB_FyP_jQdUBoYZQHNZKYq_gPwWKzUTCXpePID_dwsi-LxdkkSPHKvHvZGqlzuCA1HSFcZCBMnGBDrfV8pfhYaJeMnkp1G5FxrLchMg3-ub1BmPykn4OmKy_NvZLg0-pI9Rv/s3507/motor%20wiring_first%20position%20(slow)%20copy%202.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2480" data-original-width="3507" height="452" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrvePA8rW5dWS1alBB8-VILRRs8AGExwkdmCtqQv8gTVbyaUzOqVejqB_FyP_jQdUBoYZQHNZKYq_gPwWKzUTCXpePID_dwsi-LxdkkSPHKvHvZGqlzuCA1HSFcZCBMnGBDrfV8pfhYaJeMnkp1G5FxrLchMg3-ub1BmPykn4OmKy_NvZLg0-pI9Rv/w640-h452/motor%20wiring_first%20position%20(slow)%20copy%202.jpg" width="640" /></a></div>In this switch position power flows through the winding made of thicker wire <u>and</u> the winding made of thin wire. The circuit of the thin wire is earthed via 'Brush 2' and so links to the other, thick wire, stator winding and earth. As such, <u>all</u> the stator windings are activated. In bench tests, the current draw on a motor was about 4.4 amps.</span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizo3SaqChmUhflmnpYNu8sscMbhDKxruYPnEPvXzvMIVn0R-wv8wGW9_CT4vUjDG3YSCfCQW-Z8gxwFZHdNo8MWDnG_2jagZjRZ9T-xJW8VDRW0re9Qan1mHAhvNXDj3u2mGsVNbjPCJ_vslLYvaX8tkh6Q86_Erc3iwpF1DARuNcvRAM9M5QNgZzR/s4032/IMG_7994%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizo3SaqChmUhflmnpYNu8sscMbhDKxruYPnEPvXzvMIVn0R-wv8wGW9_CT4vUjDG3YSCfCQW-Z8gxwFZHdNo8MWDnG_2jagZjRZ9T-xJW8VDRW0re9Qan1mHAhvNXDj3u2mGsVNbjPCJ_vslLYvaX8tkh6Q86_Erc3iwpF1DARuNcvRAM9M5QNgZzR/w400-h300/IMG_7994%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Switch in 'slow' position: current draw was about 4.4 amps.</span><br /></td></tr></tbody></table><span><br /></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><b>Fast Speed - Second Knob Position</b><br /></span></span><span style="font-family: arial; font-size: small;"><span>In 'fast' mode, the contacts inside the switch <u>only</u> provide power to the <u>blue</u> contact of the switch, and so only to the blue input on the wiper motor. </span></span><span style="font-family: arial; font-size: small;"><span>Power
goes into the motor directly via the wire connected to the solder
point 'B'. The sweeper brushes on the gear inside the
gear case play no role.</span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgG9yTJlCDlFxyf8d5k0LFzE5x3F1TrcKpkcc-53vdWGVhNiPDb1kDm39-rV3ZrTwJOaCNBnozxPDzMl3ji7cTsmcpbRCva0wZ8ohga3Uur2P4znJe62BsjD4ngawtBkl-lNQjL81q7Py63uSqER50BGJShx5Phsmb_gQx9ALQAoh2BH1WvyswqCGHD/s3507/motor%20wiring_second%20position%20(fast)%20copy%202.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2480" data-original-width="3507" height="452" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgG9yTJlCDlFxyf8d5k0LFzE5x3F1TrcKpkcc-53vdWGVhNiPDb1kDm39-rV3ZrTwJOaCNBnozxPDzMl3ji7cTsmcpbRCva0wZ8ohga3Uur2P4znJe62BsjD4ngawtBkl-lNQjL81q7Py63uSqER50BGJShx5Phsmb_gQx9ALQAoh2BH1WvyswqCGHD/w640-h452/motor%20wiring_second%20position%20(fast)%20copy%202.jpg" width="640" /></a></div> In this switch position there is <u>no power</u> to, and through, the stator winding made of <u>thin</u> wire. In bench tests the current draw on the motor <u>reduced</u> to about 3.0 amps. </span></span><span style="font-family: arial; font-size: small;"><span>With the stator field reduced, the result is that the armature is able to turn <u>faster</u>. </span></span></div></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span></span></span><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjccstJ5_s2jnQOz61DMk-FZnLF1mOzYew_IgVmxGfu23B9RmlxHw8L_0TpUCUM8zmpQdCGDxf2v1ic7rEKQjemQ4q2SyqyyoRDrUQm8avNNgo7FrBp5-LjooET3E3GOcOL1pleBclIQgqj2hwMUpSpOdDhyJpt4VbaF3_xGwmqFE0WTcMpOOLK0LTK/s4032/IMG_7995%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjccstJ5_s2jnQOz61DMk-FZnLF1mOzYew_IgVmxGfu23B9RmlxHw8L_0TpUCUM8zmpQdCGDxf2v1ic7rEKQjemQ4q2SyqyyoRDrUQm8avNNgo7FrBp5-LjooET3E3GOcOL1pleBclIQgqj2hwMUpSpOdDhyJpt4VbaF3_xGwmqFE0WTcMpOOLK0LTK/w400-h300/IMG_7995%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Switch in 'fast' position - current draw is now only about 3.0 amps</span><br /></td></tr></tbody></table><span></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span>The principle at play here is apparently called "field weakening". Here is something I stole from a Google search:</span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span> </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><i>"Field weakening is a motor control technique that allows the motor to operate at speeds above its rated speed by weakening the magnetic field in the motor’s stator. By reducing the magnetic field strength, the back electromotive force (EMF) decreases, enabling the motor to rotate at higher speeds."</i></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span>So there you are....<br /></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><b>'Off' Position - During Parking of the Motor<br /></b></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span>If the wipers have been running, when the switch is put to the 'off' position, the wipers continue to run momentarily. Even though no current is flowing through the dash switch, the motor has an independent permanent supply via the black-tagged contact (solder point 'C'). </span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXAHKwWZmqTVDxQj5ENWTxue3KkMSp4R1BTMbKvxjNMiocm8Nm6_f5WtsNwPqIe39xGH6iBAXx6Or38e1VaHI6m8HyrGIt9Ho1jDYvrWKBEN46vR41AYvVmuPCLRBTdgxLjW0gGzEIdh_8FngIcZ9XMNu1Mhy_OgE6tI1YfVVM6-9GDWOBZj1TwWAn/s3507/motor%20wiring_off_parking%20copy%202.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2480" data-original-width="3507" height="452" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXAHKwWZmqTVDxQj5ENWTxue3KkMSp4R1BTMbKvxjNMiocm8Nm6_f5WtsNwPqIe39xGH6iBAXx6Or38e1VaHI6m8HyrGIt9Ho1jDYvrWKBEN46vR41AYvVmuPCLRBTdgxLjW0gGzEIdh_8FngIcZ9XMNu1Mhy_OgE6tI1YfVVM6-9GDWOBZj1TwWAn/w640-h452/motor%20wiring_off_parking%20copy%202.jpg" width="640" /></a></div></span></span><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>During the 'parking' stage, the sweeper brushes inside the gear casing - and the metal plate on the gear wheel - play a crucial role. The permanent supply to the motor via solder point 'C' leads to a sweeper brush inside the gear casing (the one with the nipple in the photo below). The sweeper brush contacts the metal disc on the gear wheel as it rotates.</span></span></div></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>As well as there being a direct wire-to-wire contact between solder point 'B' and the first thick wire coil, solder point 'B' <u>also</u> has a sweeper arm that contacts the metal disc on the gear wheel as it rotates.</span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFzqrdXfXb8eJAqo4Ry9waGM_5XUlymvckfOw_xLUzu3WdhG4MPHmvA5fLDNgPj18YdYNk86EjAovHqRLrtYmlNJu9r3-_Q0UF0OFHrpwo7IKwBDg2BEuDzDJt5hPyF5wqjJIx0CpB-0UkQA_UAnnHdBtuIg8TMdY1ggDDjjEGWxuO9kS3BPFhjm5B/s2436/IMG_7935%201%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1537" data-original-width="2436" height="253" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFzqrdXfXb8eJAqo4Ry9waGM_5XUlymvckfOw_xLUzu3WdhG4MPHmvA5fLDNgPj18YdYNk86EjAovHqRLrtYmlNJu9r3-_Q0UF0OFHrpwo7IKwBDg2BEuDzDJt5hPyF5wqjJIx0CpB-0UkQA_UAnnHdBtuIg8TMdY1ggDDjjEGWxuO9kS3BPFhjm5B/w400-h253/IMG_7935%201%20copy.jpg" width="400" /></a></div>When the dash switch is initially put in the 'off position', the motor continues to turn because power is able to enter the motor via the brush under solder point 'C', travel through the disc on the gear wheel........</span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2yO5xD7J6aKTvv3OJjDY256fQpfjJ-BvArmGVH0fY5EizUFWTQ8HjWrItcNtI6m4SG3iAkcC6BkjRJwu-MAz-uXv6-DCnb_KY406xCvAFgDQFJ74iqmkyr4g3ZKUHF0WGFZwvraiF4p3rP_QHJr09K-OZMvrxi0qAXwMy2L4CXoF3OTN_o-exPmVq/s4032/IMG_7935%202.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2yO5xD7J6aKTvv3OJjDY256fQpfjJ-BvArmGVH0fY5EizUFWTQ8HjWrItcNtI6m4SG3iAkcC6BkjRJwu-MAz-uXv6-DCnb_KY406xCvAFgDQFJ74iqmkyr4g3ZKUHF0WGFZwvraiF4p3rP_QHJr09K-OZMvrxi0qAXwMy2L4CXoF3OTN_o-exPmVq/w400-h300/IMG_7935%202.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Note the cut out segment in the outer track</span><br /></td></tr></tbody></table>.......go back out of the motor via the sweeper brush on solder point 'B' and, from there pick up on the point 'B' circuit - the thick wire circuit to the windings and armature. </span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><b>Off Position - Motor 'Parked'<br /></b></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span>Although, with the switch in the 'off' position the motor initially runs on, this running of the motor - and so rotation of the gear wheel - ultimately cuts off the power supply to the motor. </span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAZv3umkyWO4Y9YYP5nQE4u13s5e0UOTZECA5ZjvVJZzHjMSjO1sNHhR_Ey2cKZ-ckHvZwSJ61Po1fp-tJ0K1Z8qelHlI8YVFSyzcuZ9jWDynKJMJzjmpfI2MQwh_98nalHsYiM1Q5rR7Dv8_eUwHmiMOCVo3cU1mts_mjhFwjZsq-cMPJ0HZT4L-a/s3507/motor%20wiring_off_parked%20copy%202.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2480" data-original-width="3507" height="452" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAZv3umkyWO4Y9YYP5nQE4u13s5e0UOTZECA5ZjvVJZzHjMSjO1sNHhR_Ey2cKZ-ckHvZwSJ61Po1fp-tJ0K1Z8qelHlI8YVFSyzcuZ9jWDynKJMJzjmpfI2MQwh_98nalHsYiM1Q5rR7Dv8_eUwHmiMOCVo3cU1mts_mjhFwjZsq-cMPJ0HZT4L-a/w640-h452/motor%20wiring_off_parked%20copy%202.jpg" width="640" /></a></div></span></span><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>The outer circumference of the disc on the gear wheel has a segment cut out. </span></span><span style="font-family: arial; font-size: small;"><span>When the rotation of the gear wheel is such that the brush under solder point 'C' is over the <u>non-conducting segment</u>
of the metal disc, power is no longer able to flow through the disc and
back up and out via the other sweeper attached under point 'B'.</span></span></div></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifSARZLri6ZNjjVxMGlJPXdHbUljtIB5PjqjGWfs1UA4IeFT5I_68PMArkmtPoZp2RaUlRcBTiEeoCk-zvofCNmHJ9Ef9x4MekcZWbmSyQYDj5Pgg-8jIJxhkmJwTXwNo08VB3gF7RwoSmGaU5LSnn3RsE13CDiv_xTcOs_Ifl7iRZHtCeIiBty8bY/s4032/IMG_7935%202.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifSARZLri6ZNjjVxMGlJPXdHbUljtIB5PjqjGWfs1UA4IeFT5I_68PMArkmtPoZp2RaUlRcBTiEeoCk-zvofCNmHJ9Ef9x4MekcZWbmSyQYDj5Pgg-8jIJxhkmJwTXwNo08VB3gF7RwoSmGaU5LSnn3RsE13CDiv_xTcOs_Ifl7iRZHtCeIiBty8bY/s320/IMG_7935%202.jpg" width="320" /></a></div>Although there is a permanent power feed to point 'C' on the outside of the motor, it cannot access the circutry associated with point 'B' and so the motor stops turning.</span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span>When the wiper switch on the dashboard is next switched either the 'slow' or 'fast' speed positions, power flows directly through solder point 'B' (or points 'A' and 'B' together) and so bypasses the 'parked' metal disc. The motor is able to turn again.<br /></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><b>PROBLEM SOLVING</b></span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span>So what might account for the symptoms described in the Facebook mesages at the beginning of this post? </span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span> </span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span></span></span><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><b><i>Wiper Motor Switch Only Works with The Ignition On</i></b></span></span></div><span style="font-family: arial; font-size: small;"><span>The supply from the battery goes directly to the fuse. From the fuse, one branch of the supply
goes directly to the motor and the other branch goes to the wiper
switch on the dashboard. It doesn't first go through the ignition
circuit. If the ignition is controlling the wiper switch, then the
supply into the wiper switch must (wrongly) be coming from a 'switched'
source - meaning incorrect wiring or the wrong wire connected behind the
dash.</span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span> </span></span></div><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><span><b><i>Motor Get Hot Even With The Switch In The Off Position <br /></i></b></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>If the motor is getting hot, this implies there is current flowing through one of the windings. Any current going through solder point 'B' passes through both thick wire windings and the armature, so there would be motor rotation. It's basically the 'fast' mode setting.</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>Any current passing through solder point 'A' but not solder points 'B' or 'C' would flow through the thin wire winding and the second thick wire winding before going to earth. Crucially it would <u>not</u> flow through the brushes and armature and so there is no motor movement. To me, this false 'off' scenario has the potential to make the windings hot. </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>If this heating up is occuring with the switch in the 'off' postion, then it implies that the supply causing the heat is bypassing the switch. This in turn implies that the black-tagged, permanently live feed coming from the loom at the motor has been connected to the short red-tagged wire connected to solder point 'A' at the motor, instead of the wire connected to solder point 'C'. Remember that in this scenario the thin, and one thick, winding are permanently connected to a power supply and earth. Like this:</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQ8lEajLnAgjtmDdQpoJxSpgKWtfiUY74GBbix3Pt8G729Yan_sq95uhHJnOYQv6whm6b_iQVwEqgXFAnRFkQRs_R43YIGN-UlZO4te8wjQ6MlhntuNSjKAiRpjO332SbphXQFurPeN0W5ojJ5NM7f4fBOxKWeLaG_gSzskA3vyRQ-hcq3C5obTvok/s3507/motor%20wiring_POSSIBLE%20WRONG%20WIRING.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2480" data-original-width="3507" height="452" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQ8lEajLnAgjtmDdQpoJxSpgKWtfiUY74GBbix3Pt8G729Yan_sq95uhHJnOYQv6whm6b_iQVwEqgXFAnRFkQRs_R43YIGN-UlZO4te8wjQ6MlhntuNSjKAiRpjO332SbphXQFurPeN0W5ojJ5NM7f4fBOxKWeLaG_gSzskA3vyRQ-hcq3C5obTvok/w640-h452/motor%20wiring_POSSIBLE%20WRONG%20WIRING.jpg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: small;"><span style="font-size: x-small;">A wiring error like this may account for a hot motor when 'off'</span></span></td></tr></tbody></table></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span style="font-size: x-small;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><b><i>Motor Gets Hot When Switched Off, But Otherwise Works As Intended</i></b></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">I couldn't work this one out. if the heat (when off) is attributable to putting the intended solder point 'C' wire to solder point 'A', as above, and if the wiper switch is assumed to be wired up correctly, then the two wires from the switch can only go to solder points 'B' and 'C'.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">As these two contacts ('B' and 'C') are connected through the park function, then putting the wiper switch in either 'slow' or 'fast' would indeed cause the wiper motor to operate. However I think the two speeds would be the same - both 'slow' - because the thin coil winding is permamently live?</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><b><i>Switch Works - But In The Opposite Direction</i></b></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">This one I <u>really</u> couldn't work out. The inference is that the expected 'fast' switch position actually equates to 'parked' and the 'parked' position equates to 'fast'. </span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">The wiper switch has one power feed to it and two sources of power coming out - depending on the switch position. In it's intended 'off' position, no current flows from the switch - so I can't see how this can equate to a fast wiper speed. <br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><b>Other Problems</b></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">There is a joker in the pack..... In this post I have described the middle solder point on the motor (solder point 'B') as the one having a blue-tagged connection. Because of how the swiper switch works (and how the windings have to work together to produce 'slow' and 'fast' speeds), I feel that is correct. And it matches one of the workshop wiring diagrams earlier in this post.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">However if you've read my previous post <a href="http://ds-restoration.blogspot.com/2023/04/windscreen-wiper-motor-strip-down-and.html" target="_blank">HERE</a> - about my wiper motor rebuild - you will see that on my motor, and the spare one I obtained, the middle wire had the <u>red</u> tag. The blue tag was on the wire connected to solder point 'C'.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgepFYUxj_arWJbexEnpuBT7o7-ShBjppY0XLwTecc5_5li68xu-vF6B6P0vNchSOPGiHUZmqlqjb4mnHxlmq7T3_UC_F5Up0-PevSt4IUwPN4JfLdalZTfrLBSwNAp4fnHGt2qFnKdLXcI9SS5L6jbZiWjr3ZtLURFsZfvyKLMiVWi-bYCaYM-fKEh/s3264/IMG_6586%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgepFYUxj_arWJbexEnpuBT7o7-ShBjppY0XLwTecc5_5li68xu-vF6B6P0vNchSOPGiHUZmqlqjb4mnHxlmq7T3_UC_F5Up0-PevSt4IUwPN4JfLdalZTfrLBSwNAp4fnHGt2qFnKdLXcI9SS5L6jbZiWjr3ZtLURFsZfvyKLMiVWi-bYCaYM-fKEh/w300-h400/IMG_6586%20copy.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">These coloured tags are in the wrong order...</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">Until my recent motor build, a lot of my thinking - and my contribution to discussions - was based on this (mis) understanding.....Ooops! But I'm not alone. here's another wired that same way:</span></span></div><div style="text-align: left;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghCRfbeCHDIfGx5SEF1RS5RV0ViqYX_dg7MtFm5og18gL7v8dD4vpZumaBVSKYYoGRYgZ1kJP5x9mNIr8lCf0VZhMiaj6fnhQd4lYFajoz1tDEUbuVFEZLuHXWJGWVU-Qk2Sp0RHgqqEl5Do50_EtqmGy0txYoXZuvPHGDJIPCmR9VLL_Hxz-UBfc8/s1044/Maac95%20on%20Aussiefrogs.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1042" data-original-width="1044" height="399" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghCRfbeCHDIfGx5SEF1RS5RV0ViqYX_dg7MtFm5og18gL7v8dD4vpZumaBVSKYYoGRYgZ1kJP5x9mNIr8lCf0VZhMiaj6fnhQd4lYFajoz1tDEUbuVFEZLuHXWJGWVU-Qk2Sp0RHgqqEl5Do50_EtqmGy0txYoXZuvPHGDJIPCmR9VLL_Hxz-UBfc8/w400-h399/Maac95%20on%20Aussiefrogs.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Red tagged wire is in the middle position..... (photo credit Maac95)</span><br /></td></tr></tbody></table><span style="font-family: arial;">Right. Enough excuses. If you correctly wire up your wiper switch, but follow this incorrect wiring at the motor (so blue to 'wrong blue', and red to 'wrong red'), what do you get? Well....in the 'slow wipe' position, the motor runs normally.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkTsCOw1HDf9hLqCHgKaUlRA4cbJZ-chST8QRHYsG1gGZ3JYE46VQKSEgSldTNPa3TLbqZ1LGcsRRJkmjrMfdmQ6NJiqBIwFb-802BR7Vy2Uyx4DWIbdsx3YxjLSJLHrAqP9u0ok4cYx47AefxTlP1njnBLWu1ROlQo-l1acnn5JTU5l8conNU2PEe/s3507/motor%20wiring_wrong%20tags_slow.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2480" data-original-width="3507" height="452" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkTsCOw1HDf9hLqCHgKaUlRA4cbJZ-chST8QRHYsG1gGZ3JYE46VQKSEgSldTNPa3TLbqZ1LGcsRRJkmjrMfdmQ6NJiqBIwFb-802BR7Vy2Uyx4DWIbdsx3YxjLSJLHrAqP9u0ok4cYx47AefxTlP1njnBLWu1ROlQo-l1acnn5JTU5l8conNU2PEe/w640-h452/motor%20wiring_wrong%20tags_slow.jpg" width="640" /></a></div><span style="font-family: arial;"> </span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">However iIn the 'fast wipe' switch position, the motor turns momentarily until the 'park' position is hit. It then stops but is still drawing a current - so will probably get hot..... </span></span></div><div style="text-align: left;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEfD4CmNfH7sY33hPa_Qduhz2Xz35SgsnsycOThgcWazNYg1_7KVAbKOj05q9ESjZlVcHy0s0DOhqy_FDQRKdmcsNxXTPhR-GzHhrDoZOnu_dEFq-Cj0TgTJmc9OCp6lkabTBjFJBOfFpQGfYar5dnAMx1bJIaD0PsMwJAr9vBzVsDmz42swK__-T_/s3507/motor%20wiring_wrong%20tags_fast.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2480" data-original-width="3507" height="452" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEfD4CmNfH7sY33hPa_Qduhz2Xz35SgsnsycOThgcWazNYg1_7KVAbKOj05q9ESjZlVcHy0s0DOhqy_FDQRKdmcsNxXTPhR-GzHhrDoZOnu_dEFq-Cj0TgTJmc9OCp6lkabTBjFJBOfFpQGfYar5dnAMx1bJIaD0PsMwJAr9vBzVsDmz42swK__-T_/w640-h452/motor%20wiring_wrong%20tags_fast.jpg" width="640" /></a></div><br /></span><div style="box-sizing: border-box; text-align: justify;"><span style="color: black; font-family: arial;"><span><span style="text-align: left;">I tested this theory. I incorrectly connected the motor to the switch as </span></span></span><span style="font-family: arial;">described. Slow speed worked, but not fast - although the motor continued to draw about 2 amps. I didn't wait to see if the motor got hot - but I'm sure it would have done. </span></div><div style="box-sizing: border-box; text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="box-sizing: border-box; text-align: justify;"><span style="color: black; font-family: arial;"><span>So how come - if my tags are muddled - the motor on my car worked fine and had two speeds? Was there a manufacturing error somewhere at some time that Citroen
addressed simply by swapping over connections behind the dash? It's
possible, but now that my dash and original loom are out, I'll never
know how it was wired when it was originally working.</span></span></div><div style="box-sizing: border-box;"><span style="color: black; font-family: arial;"><span> </span></span></div><div style="box-sizing: border-box;"><span style="color: black; font-family: arial;"><span>It's
an easy fix though: I simply swapped the tags on the wires over! </span></span></div></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-45193543734927905422023-04-25T16:54:00.296+00:002024-02-14T08:29:12.565+00:00Windscreen Wiper Motor - Strip Down and Overhaul<div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">A clean up of the wiper motor was much needed and gave me the chance to service it. I discovered a lot along the way and plan to write a seperate '"A Quick Word About..." post on how the wiper seems to work - so this is just about stripping, cleaning and rebuilding......(I've done that now - can read about it <a href="https://ds-restoration.blogspot.com/2024/02/a-quick-word-aboutthe-mysteries-of-ds.html" target="_blank">HERE</a>).<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTw70veLjnCr9OwO8DDTH0kVvbv61awmQdf6gg4TQ2U1eQXw9I3QnIw9O6FS6iYS0_T3MebVsXseW1TrJMiILl7dhYA_gR37N02RkzStR1wlNqoA_j-2JyMCU1Le-rbcsyRo_gQacvCasBTPJWFIMDw4OjLj4YwWNRqYe4EoCA6HFWWhmQWPV6ImZD/s4032/IMG_7986_copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTw70veLjnCr9OwO8DDTH0kVvbv61awmQdf6gg4TQ2U1eQXw9I3QnIw9O6FS6iYS0_T3MebVsXseW1TrJMiILl7dhYA_gR37N02RkzStR1wlNqoA_j-2JyMCU1Le-rbcsyRo_gQacvCasBTPJWFIMDw4OjLj4YwWNRqYe4EoCA6HFWWhmQWPV6ImZD/w640-h480/IMG_7986_copy.jpg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">My wiper motor - refitted. Note that it has three solder points on the body</span><br /></td></tr></tbody></table></span><span style="font-size: small;"><span style="font-family: arial;">Just to be clear, this was a rebuild of a Bosch wiper motor from a mid/ late 1960s car, controlled by a knob on the dashboard.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4GzyDeKIlrh7-JTLzWVDkbHqeDuwWBFIDM8btj7m3NSpPF1dZVELIxPSA2cTQTW_zg-Dkqp9Ja2Le6yPNw-nD8pOCJKhTp2s6Voqi4sN9iJWMJ4VKUQ1D5OviNqLiHRGWiQ9vtGyX55m7yZB5xhE552HrOzGbmGhix4Evv78i2xxbaEevNnCtAb6N/s625/switch_Cal%20Kirk.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="543" data-original-width="625" height="348" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4GzyDeKIlrh7-JTLzWVDkbHqeDuwWBFIDM8btj7m3NSpPF1dZVELIxPSA2cTQTW_zg-Dkqp9Ja2Le6yPNw-nD8pOCJKhTp2s6Voqi4sN9iJWMJ4VKUQ1D5OviNqLiHRGWiQ9vtGyX55m7yZB5xhE552HrOzGbmGhix4Evv78i2xxbaEevNnCtAb6N/w400-h348/switch_Cal%20Kirk.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Wiper switch on the dash (photo credit: Carl Kirk)</span><br /></td></tr></tbody></table>I don't know how much of this will be relevant to later cars (October 1969 onwards) that have the wipers controlled by a stalk on the dash. The two wiper units are easy to distinguish. Later - post October 1968 - cars have FOUR cables and solder points on the gear casing. As per the photo above my car, with a two-speed mechanism, has THREE contact points and solder terminals.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I'd always anticipated dismantling and servicing the wiper motor - not least because the body and mounting brackets looked decidely tired and dirty and, if not tackled, would make my restored engine bay look shabby.......</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXkbwjNoQYAzT1i9RFcJ1bYWCJHygpQ8nqdlU-VvanDQMe-xdLstHoLrs07jKA8gbOhT22w8KjP0Rk_i7enJHHz-N3VPAQd9K0IML7FElMZ3iphLcaRHWsRl3tNK3ZS3aPGba2cQ44AmTLshCVk9d3gzY93Vz0lmBuSaqYzqRQQnUvt7rdf482ItBg/s1404/IMG_0789%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="957" data-original-width="1404" height="272" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXkbwjNoQYAzT1i9RFcJ1bYWCJHygpQ8nqdlU-VvanDQMe-xdLstHoLrs07jKA8gbOhT22w8KjP0Rk_i7enJHHz-N3VPAQd9K0IML7FElMZ3iphLcaRHWsRl3tNK3ZS3aPGba2cQ44AmTLshCVk9d3gzY93Vz0lmBuSaqYzqRQQnUvt7rdf482ItBg/w400-h272/IMG_0789%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A 'before' shot: everything looking shabby</span>.<br /></td></tr></tbody></table></span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">However the motor is held on by three bolts only accessible from behind the dash</span></span><span style="font-size: small;"><span style="font-family: arial;">.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">With the dashboard out (that's a WHOLE other job....) you can see the wiper linkage mechanism.</span></span><span style="font-size: small;"><span style="font-family: arial;"> <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuwinVb6WHCrpdh7CIRIijBY4Ghj3RXZD-plZmV-JxghJLi1dbuyaF4RU4CSCtN0DehfU2xqsDvLfRJdwzT7d0Np460N4EdRinDWDSq2Oduc1bMUCxXd2_gIyXsEjS8lNv8XNeDdjxllkCv29BYDhsPvNYu5T4w6BImqlzDJypuLUEdGK5pm9quaJk/s3264/IMG_8363%20copy.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuwinVb6WHCrpdh7CIRIijBY4Ghj3RXZD-plZmV-JxghJLi1dbuyaF4RU4CSCtN0DehfU2xqsDvLfRJdwzT7d0Np460N4EdRinDWDSq2Oduc1bMUCxXd2_gIyXsEjS8lNv8XNeDdjxllkCv29BYDhsPvNYu5T4w6BImqlzDJypuLUEdGK5pm9quaJk/w400-h300/IMG_8363%20copy.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: small;"><span style="font-family: arial;"><span style="font-size: x-small;">The wiper motor bolts and linkage are right behind the dashboard</span></span></span></td></tr></tbody></table></span></span><span style="font-size: small;"><span style="font-family: arial;">Anyway, with my dash long removed and a host of other jobs tackled, it was finally time to clean up the wiper motor. </span></span><span style="font-size: small;"><span style="font-family: arial;">The Citroen instructions for removing the wiper motor can be found at Operation D.560-1 in section 3 of volume 2 of manual 814.</span></span><span style="font-size: small;"><span style="font-family: arial;"> <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Before you remove anything, you need to make sure your wiper motor is in the 'off' position. Not just the switch, but the motor and linkage itself - it's the position with the wiper arms 'parked' at the bottom of the windscreen.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4VLSmqIi66XidddFXvo4DKeLncFGU90TfYh7IRDcgc4y6AmFMYzEmrdOLBfh8M4WUYh3knEJwMfXrFd4k8MANgkeSHIjwS9xswTHFLrJIsMe7ObMTN_FZoWICPw3dB6oFz66BhQ1ASWooDE7YaPcEjE94RkAWz6kuWSyLDbRKaJHgpyRBlDeNvBV9/s1357/park%20position.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="458" data-original-width="1357" height="135" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4VLSmqIi66XidddFXvo4DKeLncFGU90TfYh7IRDcgc4y6AmFMYzEmrdOLBfh8M4WUYh3knEJwMfXrFd4k8MANgkeSHIjwS9xswTHFLrJIsMe7ObMTN_FZoWICPw3dB6oFz66BhQ1ASWooDE7YaPcEjE94RkAWz6kuWSyLDbRKaJHgpyRBlDeNvBV9/w400-h135/park%20position.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Wiper park position for 'parallel' wipers</span><br /></td></tr></tbody></table>If your car is still all wired up, this might be as simple as operating ther wipers, and then turning them off - so they 'park'. However, my car was in pieces with no dash controls, battery - or loom for that matter - and so I needed to improvise. I actually did this with the motor still on the car of course, but the next few photos explain the principle of what I did. I connected the negative side of a 12V supply to the body of the wiper motor. I connected the positive side of the supply to the motor wire with a BLACK tag. </span></span></div></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX7ZXgU2W328EN8FcgB7xtyTEzHuAByq4X2Hg3wnfSxuWPE1sr2ws_U-Jy3TV4JeoH89BM8ydXPEaJH3XOe4Vu3s04KzKV6I7d-ggAiNE7Kyy-Zzs6MPKzhBwRVPy10GeelSazkqJgjUxvJRltvq2Z9qp2hj76JqZtPBiWlw0qO6pBgON1hfB06nib/s4032/IMG_7989.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX7ZXgU2W328EN8FcgB7xtyTEzHuAByq4X2Hg3wnfSxuWPE1sr2ws_U-Jy3TV4JeoH89BM8ydXPEaJH3XOe4Vu3s04KzKV6I7d-ggAiNE7Kyy-Zzs6MPKzhBwRVPy10GeelSazkqJgjUxvJRltvq2Z9qp2hj76JqZtPBiWlw0qO6pBgON1hfB06nib/w400-h300/IMG_7989.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Finding the 'park' position: earth and BLACK tagged wire</span><br /></td></tr></tbody></table>The wiper motor operated for a moment but then stopped. That's the 'park' position. If you do this and want to check a second time, do this: leave the negative connection on the motor body but move the power supply to the middle solder point. (in my case the wire tag was coloured red - but it's better that we just call it the <u>middle</u> wire). The motor should run continuously.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyGj_Iv-0zEG23TQeC9-Zrjk1bRbwk54wVVcbV30o1bLXybeo1FzU9WGQqp4mo40H-Vw5hWPHvpb5da_IXK6JMGCharbXJdxP93LQOuJiZvGGTWZXkP8g1vhg5n2bVaabMUYVDdvxDNVU3fNln-jA46T6rkOr1SOqXyQnH0Wk4P8vALttlePr7Xxer/s4032/IMG_7991.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyGj_Iv-0zEG23TQeC9-Zrjk1bRbwk54wVVcbV30o1bLXybeo1FzU9WGQqp4mo40H-Vw5hWPHvpb5da_IXK6JMGCharbXJdxP93LQOuJiZvGGTWZXkP8g1vhg5n2bVaabMUYVDdvxDNVU3fNln-jA46T6rkOr1SOqXyQnH0Wk4P8vALttlePr7Xxer/w400-h300/IMG_7991.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Continuous running: earth and MIDDLE wire</span><br /></td></tr></tbody></table>Now disconnect the supply and reconnect it to the wire with the black tag once again. As before, the motor should run for a moment but then stop. That should be the park point. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">With my motor in it's 'park' position, behind the dashboard I noted the angle of the motor connecting rod (the one on the motor shaft) relative to the wiper control arm on top of it. On a left hand drive car, it should look like this - with the control arm in line with, and over the top of, the motor connecting rod and approximately at a '4 o'clock' position. <br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"></span></span><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBCUMKCsURqKGYCan8zXCncn6jk2TU4HLLL9WpRJpL1EHz-ffDohLtqopP4vvVm3WagQWvPSF54qgZ5XFgFXW-XLRSRVuq7ZTrwyRW0wXGS1L5Kp7UB0r3xsibKylDR6G3-d8K5PEQe5Ab5u4YVCiqVu1USYskSLnlZbHDa1izMd_usvbSIr5n3K57/s3264/IMG_0795.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBCUMKCsURqKGYCan8zXCncn6jk2TU4HLLL9WpRJpL1EHz-ffDohLtqopP4vvVm3WagQWvPSF54qgZ5XFgFXW-XLRSRVuq7ZTrwyRW0wXGS1L5Kp7UB0r3xsibKylDR6G3-d8K5PEQe5Ab5u4YVCiqVu1USYskSLnlZbHDa1izMd_usvbSIr5n3K57/w400-h300/IMG_0795.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Wiper linkage on the wiper motor arm</span></td></tr></tbody></table></span></span></div><span style="font-size: small;"><span style="font-family: arial;"> I hope that makes sense. No? Okay, here's what Citroen say:</span></span></div><div style="text-align: left;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDMJnjnTkWxidtz3WojwHu_gOpAkeYcFuyhvP658YPMylolMJqIk4P0vsassWzbPZX8q0r_gwqNTbt8n598CNJOPlzCLEBFRpoHYDMirvNh8Epgvm8OqrOv4mPVgYd3vJpeOdAXLNITDqQEnZi5ltblCzRiD0dLpPUq20EERQRSgXNxEisC01NnvEN/s1225/park%20instructions.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="516" data-original-width="1225" height="169" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDMJnjnTkWxidtz3WojwHu_gOpAkeYcFuyhvP658YPMylolMJqIk4P0vsassWzbPZX8q0r_gwqNTbt8n598CNJOPlzCLEBFRpoHYDMirvNh8Epgvm8OqrOv4mPVgYd3vJpeOdAXLNITDqQEnZi5ltblCzRiD0dLpPUq20EERQRSgXNxEisC01NnvEN/w400-h169/park%20instructions.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Chapter and verse...</span><br /></td></tr></tbody></table><span style="font-family: arial;">I also noted the orientation of the triangular back clamp plate behind the dash. The top side has a little scallop scooped out if it helps. </span></span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWK8YBR7OUqFkUtIv40Kw9B6XKE80k0DPZXSrY9NlD_sML15Qwegf6WsTVRNVb5pdu6dznSt363cIKZgpHYViUj8Xt1qu1j1jVdv3I8-Afqa-rKGgxX7qhpXuPh_8uuayyMIjg6y1ABZK1LYFHe1WipVHG3IwRInDQuMb2T9H43YAnAXv4A9IyD3h2/s3264/IMG_0794.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWK8YBR7OUqFkUtIv40Kw9B6XKE80k0DPZXSrY9NlD_sML15Qwegf6WsTVRNVb5pdu6dznSt363cIKZgpHYViUj8Xt1qu1j1jVdv3I8-Afqa-rKGgxX7qhpXuPh_8uuayyMIjg6y1ABZK1LYFHe1WipVHG3IwRInDQuMb2T9H43YAnAXv4A9IyD3h2/w400-h300/IMG_0794.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Note the orientation of the 'scallop'</span></span><br /></td></tr></tbody></table><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">There
should be a small circlip on the tip of the wiper linkage join - where the control rod is connected to the motor connecting rod. However mine had alread fallen off somewhere behind my dash. Anyway, with
that circlip removed, the control rod can be removed from the motor connecting rod. It's a nylon bush on a metal balljoint and pops off if you lever it with a screwdriver. </span></span><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Removing the three bolts from the back triangular clamp plate enabled me to remove the wiper motor - and triangular face plate - from the car from the engine bay side. Note the triangular rubber gasket. This is a water-tight seal to stop any stray engine bay water getting behind your dash. To get at the wiper motor itself needed to remove the front face plate. To do that, I needed to remove the motor connecting rod.</span></span></div></div><div style="text-align: left;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8J9mQcgm7jBRL8lF6EwnS_R68YN1jCekMlco0PVUSAFLRnJmosTDl76Tn_Z-C3xWEWp8FMzSk1gRzJ3jvp6zgKeAqzl0XgKME57bhlBvuYNLv0Yf_E_1eYd-ZBe6h3Rht_NjGH8GMEfWy8gqHjb4EKZIxlFGOv6nNmVL0zb1OGydSt6VQv1HUJeUp/s3264/IMG_6580.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8J9mQcgm7jBRL8lF6EwnS_R68YN1jCekMlco0PVUSAFLRnJmosTDl76Tn_Z-C3xWEWp8FMzSk1gRzJ3jvp6zgKeAqzl0XgKME57bhlBvuYNLv0Yf_E_1eYd-ZBe6h3Rht_NjGH8GMEfWy8gqHjb4EKZIxlFGOv6nNmVL0zb1OGydSt6VQv1HUJeUp/w400-h300/IMG_6580.JPG" width="400" /></a></div></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Do you remember I said that it was important
to have the correct alignment between the motor connecting rod on the shaft and
the control rod? Well, for reassembly, (and with the motor still in it's 'park' position) it's equally important to have the correct
alignment between the connecting rod and the motor shaft it is bolted to - so while the motor is still together and in it's 'park' position, I put a small scratch across mine.</span></span><br /></div></div><div style="text-align: left;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgu-Y0YCqwyIjxCQPijlfhECCa4nDv_SxyjERbAidMr1MzywplLXWjQV5vorFDCwFHlaaoQhieyA4kqX7jwie6aEMa0TySxa2N7YF3Z9H-1dAY_2QpF4qF283x-xHlcJSBCAGTO8BXQfU6IHSi_SYDJwomzPGmmFHU_EsvxzKD6Mgk3z4l06eJTesvY/s4032/IMG_6352.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgu-Y0YCqwyIjxCQPijlfhECCa4nDv_SxyjERbAidMr1MzywplLXWjQV5vorFDCwFHlaaoQhieyA4kqX7jwie6aEMa0TySxa2N7YF3Z9H-1dAY_2QpF4qF283x-xHlcJSBCAGTO8BXQfU6IHSi_SYDJwomzPGmmFHU_EsvxzKD6Mgk3z4l06eJTesvY/w300-h400/IMG_6352.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Note the scratch across the drive arm and shaft</span><br /></td></tr></tbody></table></span><span style="font-size: small;"><span style="font-family: arial;">Don't worry if you forget. As per the official Citroen instructions above, the motor connecting rod can be removed and realigned later if you really need to.<br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">Removing
the nut on the motor shaft enabled me to gently prise-off the motor connecting rod. It was pushed onto splines on the shaft to stop it working
loose and rotating independently. </span></span></div><div style="text-align: left;"><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaX6LahLz_IcYSpXuMxPSwY7Xvk_GMFwVAHeFWEK2xECKw3GnJTziTkSZoo-VdE_8sqotO8K3uQWmxAprVn_PtPq0eAxPOoIW90jlFf0GBI-5RH4QS0M0eTc1kfcBnGNpaapc3ZVFKyz9qxoQpoZDRF3cC6-7xSCX99eNoZNX8Nskz38LqQ9bH0fLm/s3264/IMG_6581.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaX6LahLz_IcYSpXuMxPSwY7Xvk_GMFwVAHeFWEK2xECKw3GnJTziTkSZoo-VdE_8sqotO8K3uQWmxAprVn_PtPq0eAxPOoIW90jlFf0GBI-5RH4QS0M0eTc1kfcBnGNpaapc3ZVFKyz9qxoQpoZDRF3cC6-7xSCX99eNoZNX8Nskz38LqQ9bH0fLm/w400-h300/IMG_6581.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Shaft splines, face plate, and water-tight seal</span><br /></td></tr></tbody></table></span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">As with the back traingular clamp plate, I noted the orientation of the front face plate relative to the wiper motor body - and also which side faced the motor and which the dash. Again, a scallop on one edge served as a reference point.</span></span><br /></div></div><div style="text-align: left;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizmCnk1PvU3-4i65V_mtu2Gi5yyGFSsYsEObIb2l8N88cbxv2tYd3bLQ3vs0R_pUEfCUw4RlLaEqcPVZ8zi6tApAilqN3q1uX7Nlp27Yma-a4PKx_U9ZDRO_TwUdhBS1vShS36FYFkZ-cuhOQGyDAz-bYK8_5Mxmc_d3BAS3wYUbLxiMelzTps8uvT/s4032/IMG_6356.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizmCnk1PvU3-4i65V_mtu2Gi5yyGFSsYsEObIb2l8N88cbxv2tYd3bLQ3vs0R_pUEfCUw4RlLaEqcPVZ8zi6tApAilqN3q1uX7Nlp27Yma-a4PKx_U9ZDRO_TwUdhBS1vShS36FYFkZ-cuhOQGyDAz-bYK8_5Mxmc_d3BAS3wYUbLxiMelzTps8uvT/w300-h400/IMG_6356.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Note the scallop on the right hand edge in this photo</span><br /></td></tr></tbody></table></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The orientation of this plate is important as the holes in the plate that screw it to the motor body are not eveny spaced around the triangle: if you fit the face plate the wrongway round, when you come to mount the motor to the dash you will find your motor points at the wrong angle. It may get in the way of your 'Transpar' screen wash bottle or may even stop the bonnet closing.</span></span><br /></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The face plate was reluctant to be removed. I found that it had become stuck to a foam rubber seal around the shaft hole. </span></span><span style="font-family: arial; font-size: small;">W</span><span style="font-size: small;"><span style="font-family: arial;">ith the three plate screws removed,. Some gentle leverage freed up the plate. <br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwTRAptdP4WhPHoRrvLrj7U-gxSlO6Ft9WaPR2jozIV1900wgLxKthmp7fT4Gcp06zDbZEuSlSpKquhYo30C4Guw4Z7GMA2wF2-Vy3kroIs1exnjCFx8xA2h1ctZP8QFYDC-bTmPl238XQ4sJs4HuMX9sElmk76di0i8dVC0CEOwbALt_cDz-FL3Rs/s4032/IMG_6360.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwTRAptdP4WhPHoRrvLrj7U-gxSlO6Ft9WaPR2jozIV1900wgLxKthmp7fT4Gcp06zDbZEuSlSpKquhYo30C4Guw4Z7GMA2wF2-Vy3kroIs1exnjCFx8xA2h1ctZP8QFYDC-bTmPl238XQ4sJs4HuMX9sElmk76di0i8dVC0CEOwbALt_cDz-FL3Rs/w400-h300/IMG_6360.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Foam seal under the triangular plate</span><br /></td></tr></tbody></table></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Now...the wiper motor is earthed to the car's chassis through it's body. However from February 1968 - so partly into the 1968 model year - Citroen apparently fitted an extra 'flying' earth lead to the motor body......</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAP3eWH-VMSsb018Afm0NlUzeUrw6EyrBIaaCayP9wazQqix20lTD0ZegVIQDhKIXmPgjfYaFRUQwSie5WGW4th99Q1uEUXgKtFHikDdQbnp_UEFWyoDqLFrSxoJ_ouWJEicP7_EOSvCMBSwhp-tzrOdzkE-jI3pDVcSCFISi0QjcCqjztZ_XZZEYA/s609/earth%20lead%2049.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="399" data-original-width="609" height="263" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAP3eWH-VMSsb018Afm0NlUzeUrw6EyrBIaaCayP9wazQqix20lTD0ZegVIQDhKIXmPgjfYaFRUQwSie5WGW4th99Q1uEUXgKtFHikDdQbnp_UEFWyoDqLFrSxoJ_ouWJEicP7_EOSvCMBSwhp-tzrOdzkE-jI3pDVcSCFISi0QjcCqjztZ_XZZEYA/w400-h263/earth%20lead%2049.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Extra flying earth lead - labelled '49' in this diagram.....</span><br /></td></tr></tbody></table></span></span><span style="font-family: arial; font-size: small;">From</span><span style="font-size: small;"><span style="font-family: arial;"> other clues, I'd estimated my car was built in spring or summer 1968 - at the very least, post February 1968. </span></span><span style="font-size: small;"><span style="font-family: arial;">However the absence of that earth lead put a question mark over my estimate. But now the mystery was solved. My car had indeed had the extra earth lead. However all that was left was the end of a brass ring connector under the head of one of the screws.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC6B7ho-HUYds4r4UsnkdG5-Aw8Ed70sEAlxJj_1khgGASpAZqFnmO1pk6i7jl9winu9ayTvDm5SISMcsow-EpH9SCoVMqPCdpYbCJRkJ9WZbOeKPKnpwfVACR0YOCEMZP2VkLw6In_Ci6NXqiKHBpEoBqQqHFrn6B_OWdc8HpueWgJCdqe8Jf2GzM/s4032/IMG_6364.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC6B7ho-HUYds4r4UsnkdG5-Aw8Ed70sEAlxJj_1khgGASpAZqFnmO1pk6i7jl9winu9ayTvDm5SISMcsow-EpH9SCoVMqPCdpYbCJRkJ9WZbOeKPKnpwfVACR0YOCEMZP2VkLw6In_Ci6NXqiKHBpEoBqQqHFrn6B_OWdc8HpueWgJCdqe8Jf2GzM/w300-h400/IMG_6364.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">All that remains of the flying earth lead</span><br /></td></tr></tbody></table></span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">It would have looked like this...... <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvYx8yU9KoN7k3P64_uE2mJ_r8AqjbDyQe8ZWWhVJhDGMGP-apSoTaC599Y0NEHj1laxEB9Bsaj5sADNw6HcOSFpSB33xu5xC3vlVQorXdf9ZzIX9LPjoExNCHJxFUb_bI4CBIT8toaAx0RHfj0SFhfac0fq_NjugC40u0ARjajjBLE1xq1up3As16/s4032/IMG_6358.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvYx8yU9KoN7k3P64_uE2mJ_r8AqjbDyQe8ZWWhVJhDGMGP-apSoTaC599Y0NEHj1laxEB9Bsaj5sADNw6HcOSFpSB33xu5xC3vlVQorXdf9ZzIX9LPjoExNCHJxFUb_bI4CBIT8toaAx0RHfj0SFhfac0fq_NjugC40u0ARjajjBLE1xq1up3As16/w400-h300/IMG_6358.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Flying earth lead - as it should be</span><br /></td></tr></tbody></table>As this brass ring fixture is tucked away behind the triangular face plate, I would have to remember to make a new earth lead when I put the motor back together and before I fitted it to the car.</span></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: left;"><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">When the lid of the gear casing was removed, the gear came away with it. It was hard to see what's going on inside the casing because of all the dark, thick, grease in there. </span></span><span style="font-size: small;"><span style="font-family: arial;">In
my case, I also found a strange loose strip of metal..... I wasn't really
sure what it was - but it certainly wasn't meant to be loose and
suspended in grease.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZZYTElEJQdni18OmjK-vGiH42QuK_6hl9FwgkNqxXKmd3_H7A6fcgyAR861UcIte4zefboCQvGZm_M_JTZtpKa7X5cpcbYUtk6yiabq-W3iyB1OfLX_OlTng0b0QRPWFzs8DqTgSJbh_vgPD1xQqb1ju_Relk8LH5O3mPr6-pwA9D5HFLPUR6Wm9H/s4032/IMG_6366.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZZYTElEJQdni18OmjK-vGiH42QuK_6hl9FwgkNqxXKmd3_H7A6fcgyAR861UcIte4zefboCQvGZm_M_JTZtpKa7X5cpcbYUtk6yiabq-W3iyB1OfLX_OlTng0b0QRPWFzs8DqTgSJbh_vgPD1xQqb1ju_Relk8LH5O3mPr6-pwA9D5HFLPUR6Wm9H/w300-h400/IMG_6366.JPG" width="300" /></a></div>At some point in the
past I'd acquired a spare wiper motor, thinking it would sit on a shelf
until I had an emergency. It turned out I needed it sooner than I
expected.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0_WnWfLM3znUKJJlobdwJRhwBMXy33JP_bsvSabiGXC4PHi02sjNbsxLODMh81CmlDqHwmDlbkN5oUUb_EaZJ-CSCpJEQQlBeLC-MXQW3ZawZKpwUmNdvussfNKN0bvzaSyfBnRYeNheaSDPpDkY7T_chNXDIkou58lwQbvXmklzpEaA9tUtR1AFQ/s4032/IMG_6362.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0_WnWfLM3znUKJJlobdwJRhwBMXy33JP_bsvSabiGXC4PHi02sjNbsxLODMh81CmlDqHwmDlbkN5oUUb_EaZJ-CSCpJEQQlBeLC-MXQW3ZawZKpwUmNdvussfNKN0bvzaSyfBnRYeNheaSDPpDkY7T_chNXDIkou58lwQbvXmklzpEaA9tUtR1AFQ/w400-h300/IMG_6362.JPG" width="400" /></a></div></span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I
started to dismantle this second motor along side mine. Dismantling a second motor enabled me to
compare the two, confirm they were assembled in the same way and cement
some learning. </span></span><br /></div></div></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1NuGa4rmFstdll9Il1zJ8zxxyXZKCyS-dK2MHK7uszqLtUC3ZLtw99xJxJ_ZaoVpaS4tmDJFfzJuh3OlxRcr2f3Pkel-Rlk97cVz_xmHF8cuwqrX2KzCBB6OGKg7cd_71kMh3VVeKcFUSVhpj0VZMPx7Br9ek_eDxefz_72drUau6VPrTFmHFBKEA/s4032/IMG_6365.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1NuGa4rmFstdll9Il1zJ8zxxyXZKCyS-dK2MHK7uszqLtUC3ZLtw99xJxJ_ZaoVpaS4tmDJFfzJuh3OlxRcr2f3Pkel-Rlk97cVz_xmHF8cuwqrX2KzCBB6OGKg7cd_71kMh3VVeKcFUSVhpj0VZMPx7Br9ek_eDxefz_72drUau6VPrTFmHFBKEA/w300-h400/IMG_6365.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Compare and contrast. Spot the difference......</span><br /></td></tr></tbody></table>And that it did. It soon became clear that the broken piece in mine was an electrical contact - one of two that should be there. </span></span></div><div style="text-align: left;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPNNcIorPQUFOcqE75UVW7MF1hYBnev8rjJWPSB6F53P4AkobCJk7l-A9SHamiE_ve1SqWkKQHL3RR9DyabgeGJ-355JOTisR8tCw3flwG09NLwQ5kPoAfbDR1FH1fSaWAYo7o-G-Kwjrxc8MMVVemzNWxFNa8yo7FKXmDm5oCaw6ADyngItfi6r_1/s4032/IMG_7935.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPNNcIorPQUFOcqE75UVW7MF1hYBnev8rjJWPSB6F53P4AkobCJk7l-A9SHamiE_ve1SqWkKQHL3RR9DyabgeGJ-355JOTisR8tCw3flwG09NLwQ5kPoAfbDR1FH1fSaWAYo7o-G-Kwjrxc8MMVVemzNWxFNa8yo7FKXmDm5oCaw6ADyngItfi6r_1/w400-h300/IMG_7935.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">There should be two electrical contacts inside the casing</span><br /></td></tr></tbody></table><span style="font-family: arial;">Mine had snapped off at some point. </span></span></div><div style="text-align: left;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOGpsJPbQq1a9X5HLFTImMGfq3jcIm60owsgn0JpfdUTU9kAMuNs_cr1ZU4mx3qtnefPA0ANvoIjDba6hVgxtuIQAtH-40qGtZ9Aez2jjqEgKb_PMaa6sro9OXDTSldCUoaR6jr1r7jh21CdEWPM98N4_zIC6Dd0fNy1SaSmkSKUB7hhCNykX-Hz76/s4032/IMG_6478.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOGpsJPbQq1a9X5HLFTImMGfq3jcIm60owsgn0JpfdUTU9kAMuNs_cr1ZU4mx3qtnefPA0ANvoIjDba6hVgxtuIQAtH-40qGtZ9Aez2jjqEgKb_PMaa6sro9OXDTSldCUoaR6jr1r7jh21CdEWPM98N4_zIC6Dd0fNy1SaSmkSKUB7hhCNykX-Hz76/w400-h300/IMG_6478.JPG" width="400" /></a></div><span style="font-family: arial;"><br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-ObA7Fd0dPSDTHTuS3MPlqHM2Vz3x6wGG-NJSAo9eKJIyRVRRsdZd14M298UO8fSwr1HsibNwcOMlNwx_UpO6ii_gcSgWrvsN7DmcRt_sj8l52UmVir7MmcvkCavREKOgvOqI6ekLsQqdvWS0oD8wRkEGjdKbZ6lFTPJvMVzRansHdtQXCw8QQyg1/s4032/IMG_7922.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-ObA7Fd0dPSDTHTuS3MPlqHM2Vz3x6wGG-NJSAo9eKJIyRVRRsdZd14M298UO8fSwr1HsibNwcOMlNwx_UpO6ii_gcSgWrvsN7DmcRt_sj8l52UmVir7MmcvkCavREKOgvOqI6ekLsQqdvWS0oD8wRkEGjdKbZ6lFTPJvMVzRansHdtQXCw8QQyg1/w400-h300/IMG_7922.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The contact had snapped off</span><br /></td></tr></tbody></table></span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I'd not been heavy handed when I cleaned out the grease so I don't know how it came to be broken. Perhaps the motor had been run in reverse and it had snagged? </span></span><span style="font-size: small;"><span style="font-family: arial;">I just counted myself lucky that I had a spare motor. Whatever the cause, the learning point here is to be gentle when cleaning out this grease as there are two delicate brush
contacts in there. If you work around them with a cocktail stick, you can get the majority of grease out. In the other post that I plan to write, I'll explain what I think all these contacts are for - how the two speed wiper mechanism works. But for now, back to dismanting.... </span></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">With the case cover and gear wheel removed, the worm gear of the motor shaft was freed up. Undoing two slotted screws on the nose of the wiper body.....</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCjdPdsC7_RAkhdiNYQHeCbOtECHAw99UNDFJlPz8TfXokn3aUhLE1uP8N9p69kmi3OAfILUSowrb6vbCxNlua5UiRcGKR95EAxC_-Rv9S1rf6G22tGL_ZBLrmC6pbrQRUqW2KjGAmjk3Y_UzoxhhrG-HkH4nQjF4OXtdZ16BWT1uh7oFcE8WCyYP_/s4032/IMG_6370.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCjdPdsC7_RAkhdiNYQHeCbOtECHAw99UNDFJlPz8TfXokn3aUhLE1uP8N9p69kmi3OAfILUSowrb6vbCxNlua5UiRcGKR95EAxC_-Rv9S1rf6G22tGL_ZBLrmC6pbrQRUqW2KjGAmjk3Y_UzoxhhrG-HkH4nQjF4OXtdZ16BWT1uh7oFcE8WCyYP_/w400-h300/IMG_6370.JPG" width="400" /></a></div>....would eventually allow me to seperate the motor from the gear housing. But first I needed to do some undsoldering. At the solder points, I needed to frre-up the two wires that come from the within the motor body. BUT before you do that, first note which wire goes where.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">On both <u>my</u> motors, there was a THIN wire in a white plastic sleeve connected to the solder point on the end - I'm going to call that solder point "A" for reasons I explain in my follow up post <a href="http://ds-restoration.blogspot.com/2024/02/a-quick-word-aboutthe-mysteries-of-ds.html" target="_blank">HERE</a>. There was a THICKER wire in a brown woven sleeve connected to the middle solder point - yes, I'm going to call that solder point B'.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvuq5mB9mpiaSWnhro5UxbQCp5tdxkOD3pasMiO7dBRutF-rFpK0Qsa-1qdHu1AScYIBaJdRCye5La09ORVWdoJrwm2I4b6H9AG5RtPVBaVexq62XKLg21lKypr-BDL4ee_6qrq_t9iWyS_BqvyttRKGzjrCTtuOHmNfqiacAxBhd_Z8FXqAmf-KMW/s3264/Internal%20wire%20connections.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvuq5mB9mpiaSWnhro5UxbQCp5tdxkOD3pasMiO7dBRutF-rFpK0Qsa-1qdHu1AScYIBaJdRCye5La09ORVWdoJrwm2I4b6H9AG5RtPVBaVexq62XKLg21lKypr-BDL4ee_6qrq_t9iWyS_BqvyttRKGzjrCTtuOHmNfqiacAxBhd_Z8FXqAmf-KMW/w400-h300/Internal%20wire%20connections.jpg" width="400" /></a></div>Now, these two wires - the ones that disappear into the motor body - are soldererd under the leads that connect the motor to the loom: - the short wires with male bullet connectors and coloured tags. So to un-solder the two internal wires means also unsoldering these other wires. NOTE: you may find that your red and blue tagged wires are <u>not soldered in the same order as mine.</u> I will explain this caveat in the next post I write. I suggest you take photos before you unsolder anything and, when it comes to reassembly, put your wires back where they came from. <br /></span></span></div><div style="text-align: left;"><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">Right, with that said, in <u>my</u> case, the wire soldered to point 'A' had a <u>blue</u> tag on it and the wire soldered to point 'B' had a <u>red</u> tag on it. A third wire connects the motor to the loom. That wire has a <u>black</u> tag and connects to a third solder point, closest to the eye through which these three wires pass. Call me conventional, but I'm going to call that solder point, 'solder point 'C''.....</span></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">With all these wires unsoldered, the two screws on the nose of the motor were removed. With a bit of wiggling, the heavy motor body and it's inards were gently seperated from the alloy gear housing. You may need to work the two wires you unsoldered backwards a little, to allow the motor to be pulled free.</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBhH-jzAvEhBA_5UaQaePtwjMY2DXSHWaZT8w73N7ZLl0hyAjcqrLOwU-jAy_RzBwwcd14NoHe9tbjqMFh1TO1X0-zr8qU3Nxpc5rS_iuXsruGNVHeBtlsmTn1Uy4Cwcr_CTnvXm9nGIOoGhoRICPj4dgK1ubiAP6v4GtJVEwtnKQLB1VSPMhQJ0A5/s4032/IMG_6387.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBhH-jzAvEhBA_5UaQaePtwjMY2DXSHWaZT8w73N7ZLl0hyAjcqrLOwU-jAy_RzBwwcd14NoHe9tbjqMFh1TO1X0-zr8qU3Nxpc5rS_iuXsruGNVHeBtlsmTn1Uy4Cwcr_CTnvXm9nGIOoGhoRICPj4dgK1ubiAP6v4GtJVEwtnKQLB1VSPMhQJ0A5/w300-h400/IMG_6387.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Motor seperated from the gear housing</span><br /></td></tr></tbody></table></span><span style="font-size: small;"><span style="font-family: arial;">Behind
the nose is the carrier plate for the two bushes that provide power to
the armature. You will probably find that in wiggling the body free, the
carrier plate and brushes have been dislodged from the commutator ring on
the shaft and are now just around the shaft end. Because the brushes are
spring-loaded, this might not be immediately obvious.</span></span><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4ZpWh5dOUWoVgMzFMoFud70Q5cXP61LQZ8mZUYG2fP2o-gfdZtkyG7pBye0Sjt9ugBS4YVG_NjwXt5Xk5AyZxFcoHfT3d9cENxJm7lm-kQV0OAeewVyJjelWtFgapQkCx78yKsA_YSNnwTzyXqIVAQrnZm3pQfASrDisF3ei03eVHUB6aL0w7dMY3/s1331/IMG_6389%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1331" data-original-width="998" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4ZpWh5dOUWoVgMzFMoFud70Q5cXP61LQZ8mZUYG2fP2o-gfdZtkyG7pBye0Sjt9ugBS4YVG_NjwXt5Xk5AyZxFcoHfT3d9cENxJm7lm-kQV0OAeewVyJjelWtFgapQkCx78yKsA_YSNnwTzyXqIVAQrnZm3pQfASrDisF3ei03eVHUB6aL0w7dMY3/w300-h400/IMG_6389%20copy.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The brushes have slipped off the commutator</span><br /></td></tr></tbody></table><span style="font-family: arial;">The brushes will need to be carefully relocated back over the commutator on reassembly. Also note in the photo above, the white nylon nipple on the end of the shaft. This is to help ensure the free running of the shaft. The nose cap also has a bronze or brass bush in it to act as a bearing.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The armature was removed from the casing from the gear end and I was able to examine the motor brushes.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgU4OWrtxuBlON_7AY67zs_2-cIaNpY4LigzuFEkhGg5gDh8Xfn0VgLTAIyXULPE8ojxeHGVTmC928Rg0xgwH6p4BjZ6O_EtPwBC3uJiMAzVUkHR7fKfLYsLKu5YAkJf7_QbFKsqoNfG_-4B4xa4C-CwVErA_lNH6Yejuca7PMpQM4fHZD7wNdJi9h8/s4032/IMG_7932.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgU4OWrtxuBlON_7AY67zs_2-cIaNpY4LigzuFEkhGg5gDh8Xfn0VgLTAIyXULPE8ojxeHGVTmC928Rg0xgwH6p4BjZ6O_EtPwBC3uJiMAzVUkHR7fKfLYsLKu5YAkJf7_QbFKsqoNfG_-4B4xa4C-CwVErA_lNH6Yejuca7PMpQM4fHZD7wNdJi9h8/w400-h300/IMG_7932.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The motor brush assembly</span><br /></td></tr></tbody></table>These were not too badly worn at all, but if you think yours need replacing, they are held in place by small coiled springs. I've got no idea what the sizes would be for replacement brushes.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK9znDz0uPXD0XkFoXaJpvfqkzO9vCgYD-j-Ff1H58D1Ni_-Xas9Jjyv5Dm72yTZzTABtj2uiKdix20NDoHfSd7ew_FnhAkaWp11SwzZCQ4bl6P6S4jooqbBwxHpar4GN3cEjNkPv_Ap_TQMdCzUSScQcgZBWGaarlnp4nZWvS3mhnnL2dY6R0-ITE/s4032/IMG_7943.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK9znDz0uPXD0XkFoXaJpvfqkzO9vCgYD-j-Ff1H58D1Ni_-Xas9Jjyv5Dm72yTZzTABtj2uiKdix20NDoHfSd7ew_FnhAkaWp11SwzZCQ4bl6P6S4jooqbBwxHpar4GN3cEjNkPv_Ap_TQMdCzUSScQcgZBWGaarlnp4nZWvS3mhnnL2dY6R0-ITE/w400-h300/IMG_7943.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The brushes are held by coiled springs</span><br /></td></tr></tbody></table>I cleaned the commutator on the armature. I think this is the best/ only photo I have. It's the shiny copper part in the background here.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEif2ZbpXA2DvL2VMPlmP-TD6ED64CpiX30TWlVks4CiBVEPb-B-W8fkFxeOnLiFdivHwsH8nfBQUp66jFXTHrBT94913ObX3et4GpSUc-7p-cRjXs6GyqlTObCyb8l_ci3TQPiVhwvSsODsApWrvOCUOu9FhE1ZUB-Znrf-PHwYFhwvef44nloSjtur/s4032/IMG_7948.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEif2ZbpXA2DvL2VMPlmP-TD6ED64CpiX30TWlVks4CiBVEPb-B-W8fkFxeOnLiFdivHwsH8nfBQUp66jFXTHrBT94913ObX3et4GpSUc-7p-cRjXs6GyqlTObCyb8l_ci3TQPiVhwvSsODsApWrvOCUOu9FhE1ZUB-Znrf-PHwYFhwvef44nloSjtur/w300-h400/IMG_7948.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Commutator in the background....</span><br /></td></tr></tbody></table>I spun it in my hand and used fine grade emery cloth to polish it up. I then carefully used a knife blade to clean out the muck between each segment.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">The gear wheel was pulled free from the casing which was de-greased. I cleaned up and examined the gear wheel. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpa_yV_jHSb-4Dq9zZ0kZjiyH__Jldkei2cdsC3aVoJvhDJvY8BJNNwE1yeCjUOyrXJ_yQqIIf5-6rbBtVvxaLJooeNUQVCjlcYXTkpVT9ReoNs-y4AmH_QkeOgg6m8cM1anGvYuaPMj9ft0AjrHL4XPttR1mP8ygyI3FxiqyrKF3rgYWrH8dUzs9r/s4032/IMG_7935%201.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpa_yV_jHSb-4Dq9zZ0kZjiyH__Jldkei2cdsC3aVoJvhDJvY8BJNNwE1yeCjUOyrXJ_yQqIIf5-6rbBtVvxaLJooeNUQVCjlcYXTkpVT9ReoNs-y4AmH_QkeOgg6m8cM1anGvYuaPMj9ft0AjrHL4XPttR1mP8ygyI3FxiqyrKF3rgYWrH8dUzs9r/w400-h300/IMG_7935%201.JPG" width="400" /></a></div><span style="font-family: arial;">Other than saying that you can see how the marks on the gear wheel line up to the two copper sweeper arms sticking out of the gear case, I will save any explanation of what is going on for my next post.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I didn't dismantle the motor any further. On the gear casing there was a small grub screw covered with a blob of blue paint.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCLHuVLFMDqK5wM5udaF_MtfCVIV-JkT9MRIEHKFfyxOyKehRLUGSMNoCpqsivmrV-eUqEpbZm4VgSMhAZB3GWUDEQbCOeUZPE6uJ5YXcFPnO0p9iuke9-mr2EC-iinzxLql7xLE8e5cRM6AZG9kQV7BHwef29mxNhJjksIjNVY1F0bsay1R5i631s/s4032/IMG_7996.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCLHuVLFMDqK5wM5udaF_MtfCVIV-JkT9MRIEHKFfyxOyKehRLUGSMNoCpqsivmrV-eUqEpbZm4VgSMhAZB3GWUDEQbCOeUZPE6uJ5YXcFPnO0p9iuke9-mr2EC-iinzxLql7xLE8e5cRM6AZG9kQV7BHwef29mxNhJjksIjNVY1F0bsay1R5i631s/w400-h300/IMG_7996.JPG" width="400" /></a></div><span style="font-family: arial;">The other end of the screw contacts a white plastic nipple on the worm gear end of the rotor shaft. It looks as though this screw is used to set the free play of the gear. I left this alone. Not least because the broken metal contact meant I would be using my spare gear casing.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I put clingfilm around the brush carrier to protect it and masked off the gear end of the body, then I stripped the paint off, de-rusted it and painted it up.I had planned to get the gear casing and nose vapour blasted to restore the 'just cast' look to the alloy but, given the bushes/ bearings in the two parts, and given how delicate the motor contacts seemed to be, I decided to put them in my ultrasonic bath instead. That was partially successful and removed some dirt but not as good as vapour blasting. I avoided the temptation to use metal polish on the alloy parts, partly because they were complex shapes and I wouldn't have been able to polish all areas, but mostly because it leaves the parts with a chrome-like finish - which I didn't want. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I did indulge myself by having the triangular back and face plates re-coated in zinc after carefully removing the rubber seal. </span></span><span style="font-size: small;"><span style="font-family: arial;">The back plate is hidden behind the dashboard but the face plate can be seen on the engine bay side.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfyhZ13qPa0Cr3Ls8Vf8LTvE0_rQ3hLemm40EPmLJ3NuH0s5wJtDBrS1Iil1qNSOGnWOzAkOO9eaJlYVK5NLOw7Od2vBWPs1zl-_8J4A7IdPM6DEXHl36O94YTxGmiB0Uko-T3bjJI9MD4WTNDjNdd7GLCC5vFRIlYnt5tiFS7_D9Azq1tsOfdqhEO/s4032/IMG_6482.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfyhZ13qPa0Cr3Ls8Vf8LTvE0_rQ3hLemm40EPmLJ3NuH0s5wJtDBrS1Iil1qNSOGnWOzAkOO9eaJlYVK5NLOw7Od2vBWPs1zl-_8J4A7IdPM6DEXHl36O94YTxGmiB0Uko-T3bjJI9MD4WTNDjNdd7GLCC5vFRIlYnt5tiFS7_D9Azq1tsOfdqhEO/w400-h300/IMG_6482.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Face plate with the rubber seal removed</span><br /></td></tr></tbody></table> After that, it was back to reassembly. Which was basicaly the reverse of disassembly. I half-packed the gear case with light grease. Although the stuff I scraped out was dark and hard - like heavy grease - I suspect that it had just thickened up over the years. I tried Googling motor grease and concluded that a light grease should be good enough. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I introduced the armature to the casing, making sure that the wires on the stator windings did not rub-on or obstruct the armature.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNeDb0VIT9qjv0pcLGNF0_a4KuQIWXIrGmM5dxRHkmXR6lxMJYJBfN4EJeOfmFPJUlOx1iwAafA0tfeJY4Av2wvSjmFV0KbVIf1l2nDULWq01KcvP9UnbPHs6kvo7F_3u8_du7GcNdeYnCr7UzzC8LnOjQ9jZUOaBdQvl48fWg4ANgS7AOVF_0aI1x/s4032/IMG_7927.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNeDb0VIT9qjv0pcLGNF0_a4KuQIWXIrGmM5dxRHkmXR6lxMJYJBfN4EJeOfmFPJUlOx1iwAafA0tfeJY4Av2wvSjmFV0KbVIf1l2nDULWq01KcvP9UnbPHs6kvo7F_3u8_du7GcNdeYnCr7UzzC8LnOjQ9jZUOaBdQvl48fWg4ANgS7AOVF_0aI1x/w300-h400/IMG_7927.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Make sure the winding wires are clear of the armature</span><br /></td></tr></tbody></table><span> </span>With the armature back inside the casing......</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1p0XK-WZG2ZhTN3sFPa3sBVCwnkveZzVhdMQG7xQ6jOfy69hfZj863SK9LVwKc-WhyphenhypheneBDeR-snDS9CZtWz4LGg5ZHMZE7eSZ8GqWaSUdMwZGpQ_pBxQI5zjss00sklvzr7R36noYUSgn-b9BAGvTKY2_hMT6cQfjuHFbP7-v4VteY4U5Z-kkF63Od/s4032/IMG_7951.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1p0XK-WZG2ZhTN3sFPa3sBVCwnkveZzVhdMQG7xQ6jOfy69hfZj863SK9LVwKc-WhyphenhypheneBDeR-snDS9CZtWz4LGg5ZHMZE7eSZ8GqWaSUdMwZGpQ_pBxQI5zjss00sklvzr7R36noYUSgn-b9BAGvTKY2_hMT6cQfjuHFbP7-v4VteY4U5Z-kkF63Od/w400-h300/IMG_7951.JPG" width="400" /></a></div><span style="font-family: arial;">.....I used a screwdriver to push back the two carbon brushes against their springs and locate them over the commutator.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0Zeg4Vo6tysDv8diXjoOBcF-puq-ES4jcF2Kd8y3ODw4JKTuf9Go7nw7pk2AL4HO9p0Hq_9nnnGuLlueDHCz9S-1SAr3aJs93AQ3FjxxhlkwalkEgvubNS8WRpQt5s7mO1j3pkXebAnsXS4eeYb7eE6GAfjd0Ny-lG9SAkQqpwARDrmTXMfaBbuL6/s4032/IMG_7952.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0Zeg4Vo6tysDv8diXjoOBcF-puq-ES4jcF2Kd8y3ODw4JKTuf9Go7nw7pk2AL4HO9p0Hq_9nnnGuLlueDHCz9S-1SAr3aJs93AQ3FjxxhlkwalkEgvubNS8WRpQt5s7mO1j3pkXebAnsXS4eeYb7eE6GAfjd0Ny-lG9SAkQqpwARDrmTXMfaBbuL6/w400-h300/IMG_7952.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Note the irregular shape of the brush carrier. This is to hold it in the motor nose</span><br /></td></tr></tbody></table><span style="font-family: arial;">I put a small dab of grease on the motor shaft where it would pass through it's bush. The ends of the two wires from the winding were threaded through, and out of the gear casing and the gear casing and body were gradually introduced.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNHLyD4UAqgiBjRWOHaRe6qkc2aBIex0Ves1htsBBCvZrurFgI9WX4oo9vycMsOem0BHcDbWhHxEYecSGmA_0U3aWJwBCYkRNt4dZGob0Io5V3YUWJDA7b_nykxKe2cp6qtTkgdCetWKiaKZwQ-JsaNK4ZmvlF6cTZW2Aw8bepjgMnFHz69cULHl0z/s4032/IMG_7926.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNHLyD4UAqgiBjRWOHaRe6qkc2aBIex0Ves1htsBBCvZrurFgI9WX4oo9vycMsOem0BHcDbWhHxEYecSGmA_0U3aWJwBCYkRNt4dZGob0Io5V3YUWJDA7b_nykxKe2cp6qtTkgdCetWKiaKZwQ-JsaNK4ZmvlF6cTZW2Aw8bepjgMnFHz69cULHl0z/w400-h300/IMG_7926.JPG" width="400" /></a></div>Pulling the two wires through the gear casing as I went, and holding the motor brushes on the commutator so that they did not slip off, I pushed the body and armature onto the gear casing so that the worm gear went to the bottom of it's tunnel and the motor body was flush with the casing. Note that there is a little tab on the motor body. <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_t7xPw-bKWsxyO5Lp74YaX8H4ZUNcbK9p7ctEE2s40qwrJmkjgDw0K526TRgfArOaV48YCd2tZwESgpwnL3yoHEwqA_DwED4KKfVxXpcBRfaenY2WwAMMkFia_8ctwpU3_PHmkytv0Js4dBNtPrm-Y4dAbaKeoTErYR6HbjcguJw8fyos5_Uu4jsl/s4032/IMG_7928%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_t7xPw-bKWsxyO5Lp74YaX8H4ZUNcbK9p7ctEE2s40qwrJmkjgDw0K526TRgfArOaV48YCd2tZwESgpwnL3yoHEwqA_DwED4KKfVxXpcBRfaenY2WwAMMkFia_8ctwpU3_PHmkytv0Js4dBNtPrm-Y4dAbaKeoTErYR6HbjcguJw8fyos5_Uu4jsl/w300-h400/IMG_7928%20copy.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Note the locating tab (arrowed)</span><br /></td></tr></tbody></table><span style="font-family: arial;">The tab corresponds to a cut out on the casing.</span></span><span style="font-size: small;"><span style="font-family: arial;"> <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6Qwl2aLnKhLAzZ2VQAokGT-0n_3oW7ph9avMvIxjbNUO4s4MbhGCcsT_N9qarrAj2XDZGYq0GIxbM_vDWX3fqJD2oQ3T0Qfqs4QnZMFPfa8LYZpxUmRpfRnygorM-3292xGH1UtWjNllkgoCd8Y4gFzDjzpn81bp3k55sAoz37iSuigmlQQZWiFSp/s4032/IMG_7947%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6Qwl2aLnKhLAzZ2VQAokGT-0n_3oW7ph9avMvIxjbNUO4s4MbhGCcsT_N9qarrAj2XDZGYq0GIxbM_vDWX3fqJD2oQ3T0Qfqs4QnZMFPfa8LYZpxUmRpfRnygorM-3292xGH1UtWjNllkgoCd8Y4gFzDjzpn81bp3k55sAoz37iSuigmlQQZWiFSp/w300-h400/IMG_7947%20copy.jpg" width="300" /></a></div>That
means that the body only fits on the casing in a particular way. I suspect
this is to line the wires up correctly with the hole in the gear casing.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I put a small dab of grease in it's bush and refitted the nose cone. There are 'keyed' cut outs in the edges of the brush plate that locate it in the nose cone. If the plate is not correctly seated in the nose cone, the nose cone will not fit correctly on the end of the motor body.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhON5nqnMug5a0SieoCggoLU_vFZVjQI_2o3-8DGX_3m0N-TcC6HS9tN4rsIx4fSb4lRoEGrCJqB_XAZU4BeNNk7f6jBfaA-irlNSZOMHppHFzse2HnZcy1SzBlMt495q8I6DGtWkA4-rpU6ER2jfTEMfSzVvuUOU7mf7plbWeGOoh9mussOeA-r7Bz/s4032/IMG_7930.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhON5nqnMug5a0SieoCggoLU_vFZVjQI_2o3-8DGX_3m0N-TcC6HS9tN4rsIx4fSb4lRoEGrCJqB_XAZU4BeNNk7f6jBfaA-irlNSZOMHppHFzse2HnZcy1SzBlMt495q8I6DGtWkA4-rpU6ER2jfTEMfSzVvuUOU7mf7plbWeGOoh9mussOeA-r7Bz/w400-h300/IMG_7930.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Note the irregular shaped ends of the brush carrier</span><br /></td></tr></tbody></table>Also bear in mind that you will need to line up the
screw holes in the nose with their counterparts on the body. However a</span></span><span style="font-size: small;"><span style="font-family: arial;">void
twisting the brush carrier as you fit the nose as you risk breaking or trapping a wire
against the rotor.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I
found it quite tricky to push the long screws through the nose and
catch the threaded holes in the body. The rotational alignment of the
nose is crucial and patience is needed to avoid cross-threading in the soft alloy gear casing.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">At this stage, I just did up the two long screws just less than finger-tight. Before I went any further, I powered up the motor: I connected the positive of a 12v supply to the thick cable sticking through the body (the one with a brown woven outer) and the negative to the body of the motor. While it span, I adjusted the position of the cap and body relative to the gear casing to make sure the armature spun freely and without any scraping noises. Holding that position, I tightened the two screws through the body - continuing to make sure that the armature was able to spin freely. At the worm gear end I check for free play and decided that no adjustment of the small grub screw was necessary. Once happy, I disconnected the power.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">I part filled the gear housing with grease. </span></span><span style="font-size: small;"><span style="font-family: arial;">I greased the shaft of the gear and it's teeth, and refitted it to the gear casing cover, testing that it spun freely. I added more grease to the casing - leaving enough space for the gear but also not over-filling the housing. I refitted the casing cover and it's four screws - remembering to add a short extra flying earth lead. (In fact all I did was pinch the lead off my spare motor).</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">After refitting the triangular face plate and it's seals - paying attention to the scallop edge of the plate - the last task was to re-solder all the contacts. Of the two wires coming from inside the motor, the thick wire in the brown woven sleeve goes to the <u>middle</u> of the three solder points. The thin wire in the white plastic sleeve goes to the first solder point - the point I labelled as 'A' earlier in this post. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">At the same time, I re-soldered the three colour-coded and bullet ended wires that connect the motor to the loom. As </span></span><span style="font-family: arial; font-size: small;"><span>I
said earlier-on that the connections on your solder points might be
different to mine. On the two motors I have the connections are as per
this 'before' photo:</span></span></div><div style="text-align: justify;"><div style="text-align: left;"><span style="font-family: arial; font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC1vSHnQU4m_djRes8chLAWyea7VhWZ_qx1wUSJiymt2Mm7IyMqEBErdN5W9pmsxEd5tFWyvd4_vjhJkdnodKygkL_OzCZjnAUgkSn4KksogYuqn5nsv60djR64ZIBydObo_dCk_7ErrS-m7szyV5FdVY1djbkUt97S5s3tIgeuu-5wrfSLvLLk0IH/s3264/IMG_6586%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3264" data-original-width="2448" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC1vSHnQU4m_djRes8chLAWyea7VhWZ_qx1wUSJiymt2Mm7IyMqEBErdN5W9pmsxEd5tFWyvd4_vjhJkdnodKygkL_OzCZjnAUgkSn4KksogYuqn5nsv60djR64ZIBydObo_dCk_7ErrS-m7szyV5FdVY1djbkUt97S5s3tIgeuu-5wrfSLvLLk0IH/s320/IMG_6586%20copy.jpg" width="240" /></a></div></span><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>The
blue-tagged wire is first (my 'solder point 'A''), the red-tagged wire is in the middle (point 'B') and the
black-tagged wire is at the end (point 'C'). BUT I SUSPECT THESE TWO ARE THE WRONG WAY ROUND. If your red and blue wires are the other way round, and your motor and wipers were working before you took your motor apart, I strongly suggest you connect your three wires up as they were before. </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>And then onwards with refiiting. As the motor has been disassembed and the gear wheel moved/ removed, you need to find the 'park' position again......connect the positive of a 12V power supply to the black tagged wire connected to solder point 'C' and the negative to the motor body. The motor should run momentarily then stop - that's the 'park' position. </span></span></div></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>I offered the face plate and motor assembly up to the hole in the bulkhead, then offered up the back clamping plate from behind the dash - again paying attention to the orientation of the scallop on one side. It should be along the top edge of both plates. The two plates were then bolted together and it simply remained to connect the motor back up to the linkage.<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span><br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>I fitted the short motor connecting rod over the splines of the motor shaft. If you marked the relative positions before, then re-align those marks. Here are mine again:</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiug3Yq_ZX5C3JemC7M1tK2nXo2d7cV2DgiKOIkKWAelaKsPf5FnN1HT8wHH7RJpim9WVv9BvgpdRkdwC-2EAapAp0hO7og4u9hzRZhGIx_qh4ZOJxa4BBAaSHguyAekzDEmtI37KSo5pY2EwrGFu2i0jUCUnAbO7ghM5P_iEPPSiWOBCOhI3-RJrHP/s4032/IMG_6352.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiug3Yq_ZX5C3JemC7M1tK2nXo2d7cV2DgiKOIkKWAelaKsPf5FnN1HT8wHH7RJpim9WVv9BvgpdRkdwC-2EAapAp0hO7og4u9hzRZhGIx_qh4ZOJxa4BBAaSHguyAekzDEmtI37KSo5pY2EwrGFu2i0jUCUnAbO7ghM5P_iEPPSiWOBCOhI3-RJrHP/w300-h400/IMG_6352.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Reference marks on the shaft and connecting rod</span><br /></td></tr></tbody></table>The connecting rod should be at about a '4 o'clock'' angle. I refitted the nut but did not fully tighten it at this point. I aligned the wiper linkage so that the control rod overlaid the connecting rod. </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>If yours <u>doesn't</u> overlay it, pull the motor connecting rod off the splines of the motor shaft and move it until the two <u>do</u> align. If you are having trouble with this step, it might be worth checking that your motor is in the 'park' position.<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>I was satisfied with my alignment, </span></span><span style="font-family: arial; font-size: small;"><span>and tightened the nut holding the motor connecting rod to the motor shaft. </span></span><span style="font-family: arial; font-size: small;"><span>I greased the nylon socket and pressed the control rod end over the knuckle of the connecting rod. I sourced and fitted a securing circlip.<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGXOMtDULmQRh7cKlxhrlTzTJPsN4gU6YHaO_lY2R48a0SuODfVQc7JBodJDQKIkT13-wQj4Dsc0d5_kVUF5zgkFcixV3hLuJ_Fv2ESLCPNgFdV-9L46KH0m11UEDLyZcaJWjNY4VYZY0DKb01il31DheaN-jqfiLdwV_TjtMzkVE5B6xVPQb5LrQI/s4032/IMG_6680.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGXOMtDULmQRh7cKlxhrlTzTJPsN4gU6YHaO_lY2R48a0SuODfVQc7JBodJDQKIkT13-wQj4Dsc0d5_kVUF5zgkFcixV3hLuJ_Fv2ESLCPNgFdV-9L46KH0m11UEDLyZcaJWjNY4VYZY0DKb01il31DheaN-jqfiLdwV_TjtMzkVE5B6xVPQb5LrQI/w400-h300/IMG_6680.JPG" width="400" /></a></div></span></span><span style="font-family: arial; font-size: small;"><span>That's pretty much it, but read on......</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>With the dashboard out it was difficult to check that everything works as intended from the dash knob. So I used a portable 12V supply to test functionality.........</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKO5ghovC5h2ssjwTwjBOpHZw-fbkGbKHdT2S-IgmxnuntBsTDoJU5z13goFtsHB_dAOAxcjIXBo8oUrsrkBG3FfO7e_rVGVTsizY01qE84AfR4Vc2smgkPp5IxIzYTHZiFrKoGHdaCfYOTwPIlmH3MvaNaLgcl4bcJ6MSBN_NgZq-o69WDGykUrMP/s4032/IMG_8003.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKO5ghovC5h2ssjwTwjBOpHZw-fbkGbKHdT2S-IgmxnuntBsTDoJU5z13goFtsHB_dAOAxcjIXBo8oUrsrkBG3FfO7e_rVGVTsizY01qE84AfR4Vc2smgkPp5IxIzYTHZiFrKoGHdaCfYOTwPIlmH3MvaNaLgcl4bcJ6MSBN_NgZq-o69WDGykUrMP/w400-h300/IMG_8003.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Testing functionality....</span><br /></td></tr></tbody></table>......<u>and my wipers didn't work</u>!
</span></span><span style="font-family: arial; font-size: small;"><span>'Park' and 'slow' worked as intended, But in the 'fast' position there was a current draw but the motor didn't turn. I remember at least two other people with a wiper problem where the motor got hot and this could be the scenario that led to that.<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>I was sure I had resoldered my colour-tagged wires back as they had been removed, but </span></span><span style="font-family: arial; font-size: small;"><span> I found I had to reverse the red and blue connections from my power supply (so that blue from the switch and loom went to the <u>middle</u> solder point) to get </span></span><span style="font-family: arial; font-size: small;"><span>both wiper speeds and 'park' to
operate correctly from the switch.</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6B4uWNaqj4V2oefeFxlTMqWsvvXBoxKhVO8XJoh-ok69rOdEd4XElmUGqYH7anQDMaZca3JWE9C60rk-rHuOHsqLdJzJZHuZKL8aUEDveKZUXuT-QyED9ihkBjD0zHE8bk9gl_LNMGMrgz-vxYA1LuArpuBdSAFPkuU9Ch6mHGcDrV11pn7COavSL/s4032/IMG_8004.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6B4uWNaqj4V2oefeFxlTMqWsvvXBoxKhVO8XJoh-ok69rOdEd4XElmUGqYH7anQDMaZca3JWE9C60rk-rHuOHsqLdJzJZHuZKL8aUEDveKZUXuT-QyED9ihkBjD0zHE8bk9gl_LNMGMrgz-vxYA1LuArpuBdSAFPkuU9Ch6mHGcDrV11pn7COavSL/w300-h400/IMG_8004.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">For me, blue and red connections reversed restored correct operation</span><br /></td></tr></tbody></table></span></span><span style="font-family: arial; font-size: small;"><span> For the moment, just know that if you find the same problem, this doesn't stop your motor being
refiitted or stop it working as intended. As I found out, you just might need to swap the red and blue wires over at their plug connections or where they join the switch behind the dashboard. And if you want to keep all your colour coding correct, once you've swapped your wires, just swap over the coloured tags as well so that red still connects to red and blue to blue. That's what I did!<br /></span></span></div><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span>I'll revisit all of this, and more, in my next post on <a href="https://ds-restoration.blogspot.com/2024/02/a-quick-word-aboutthe-mysteries-of-ds.html" target="_blank">the mysteries of the wiper motor.</a>....... </span></span></div></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span> </span></span></div></div></div></div></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-8113059789953284492023-04-22T07:11:00.011+00:002024-01-11T19:37:50.523+00:00Refitting The Hydraulic Gear Selector (aka the 'Gear Brain')<div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">The hydraulic gear selector (aka 'gear brain') is back on the car. </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIe_aqZhGGadz_DlPd1ChEsIoAiw0ToBBpHmypLVYrRjMz_ZBpPxJeIP4TzqT-S-fy4EjZrya1wAa97S4S36qvb48cYvXdl9UlDsVsJQQ8I0-e1zMFVkGPgEm9EYNZbltijYILCDuDWvRRpJAdJ6J9p3T3U9bgCvhF6BPSUb515bEKbk1PeOLYsFeo/s4032/IMG_6639%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIe_aqZhGGadz_DlPd1ChEsIoAiw0ToBBpHmypLVYrRjMz_ZBpPxJeIP4TzqT-S-fy4EjZrya1wAa97S4S36qvb48cYvXdl9UlDsVsJQQ8I0-e1zMFVkGPgEm9EYNZbltijYILCDuDWvRRpJAdJ6J9p3T3U9bgCvhF6BPSUb515bEKbk1PeOLYsFeo/w640-h480/IMG_6639%20copy.jpg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The 'gear brain' on a bvh car</span><br /></td></tr></tbody></table><span style="font-size: small;">Fitting is a little fiddly but otherwise simple. Setting it up - as part of the fitting - requires a bit more attention. Instructions can be found at Operation Dh.334-1 in volume 2 of manual 814.<br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">The first task is to 'lock' the brain in the 'first gear' position. This is done by aligning the hole through the slide valve with the hole on the body of the selector.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNMlFamPU0F99g00WMCxmsImcFqf8IM2iDWChcwK5GCdWs3_RnTJC5uPxjCWIIJsG-Pmky0NIoMcNRLxzPfNASLmQ14otr6BBWnlgQxwpoEgi0vrMm4Lu3vnysqDNPxmyo-sHmAttQurnJtpW6_JUOEG_w4uCKS3dpZTW7Zdl4hBd17H3aNVDLoooq/s4032/IMG_6646.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNMlFamPU0F99g00WMCxmsImcFqf8IM2iDWChcwK5GCdWs3_RnTJC5uPxjCWIIJsG-Pmky0NIoMcNRLxzPfNASLmQ14otr6BBWnlgQxwpoEgi0vrMm4Lu3vnysqDNPxmyo-sHmAttQurnJtpW6_JUOEG_w4uCKS3dpZTW7Zdl4hBd17H3aNVDLoooq/w300-h400/IMG_6646.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Hole for the gear brain setting pin</span><br /></td></tr></tbody></table>The slide valve is locked by inserting a pin through the hole - Citroen tool 2429-T. </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7tUfk0Fji_10FdkGuqAGmAtP6LWVQCE_dU8k6MvnL8C-f2VfX-DjwCMsTbBx3JybQSd2bTcORtgyl1tcgbh-kncuV-frFYo38EujSSdGqV5oGhQh9KKz9aGG0nNpNV5dsayBCP7XWtyT5ivpArk0LlwOeIDxsvoC3UrAUR_GdUdtu-v8UvQTr8WmZ/s3264/IMG_0213.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7tUfk0Fji_10FdkGuqAGmAtP6LWVQCE_dU8k6MvnL8C-f2VfX-DjwCMsTbBx3JybQSd2bTcORtgyl1tcgbh-kncuV-frFYo38EujSSdGqV5oGhQh9KKz9aGG0nNpNV5dsayBCP7XWtyT5ivpArk0LlwOeIDxsvoC3UrAUR_GdUdtu-v8UvQTr8WmZ/w400-h300/IMG_0213.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The mythical 'tool 2429-T'.....</span><br /></td></tr></tbody></table>The manual says this pin needs to be 3.94mm in diameter. That's pretty precise! I found that a 4mm twist drill was too big but given the tolerances in drill bits, you might find one that fits. Don't be tempted to use some thing of a smaller diameter as you need to set the slide valve as precisely as possible. You dont want to jam a pin in, but you want it to be as snug as possible.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpvGpPAqOK8jbqP0wHlp1TUAGc26JhiNnPIklTlpbmlLlHp3gJfgMrn0x9fF7ZU4Pz50EqYOfVUIWZc_YrOO8NHZudORD6xBeoUTolAVSOjAYJUj8xUYZIOSEEam2p3axXUpaDd4uVGsC9KjlURDSntsZAHJjCpREW1JlTPDALiX6R1Yc10-XjVD1f/s4032/IMG_6647%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpvGpPAqOK8jbqP0wHlp1TUAGc26JhiNnPIklTlpbmlLlHp3gJfgMrn0x9fF7ZU4Pz50EqYOfVUIWZc_YrOO8NHZudORD6xBeoUTolAVSOjAYJUj8xUYZIOSEEam2p3axXUpaDd4uVGsC9KjlURDSntsZAHJjCpREW1JlTPDALiX6R1Yc10-XjVD1f/w300-h400/IMG_6647%20copy.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Setting Pin. The red tape indicates 3cm depth</span><br /></td></tr></tbody></table><span style="font-size: small;"></span><span style="font-size: small;">For the correct setting, the pin needs to disappear about 3cm into the body of the selector. It's possible to have the slide valve hole lined up BUT the slide valve rotated 180 degrees out. If this is so, the pin will fit partly only through the valve - apparently 'locking' it - but internally, the grooves/ channels in the valve will not line up as they need to.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNcEnrTL8y8jRgcjCLl7K9yg5LFM-wcVH8R5pWSUe-eXC3NgqJw5jvUOBrtfLMj8DdOIO4slOdATjBik6jDQJdbY7NE3lqmBOmfIn3GiybbRQQ5M2cv6LuBjLdbFczyx56fCfCBGhW74bNWWApYOahCH6yZoJN4lvrp-jASvW_GKSSnvGbe3NOiohT/s3613/IMG_6533%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1443" data-original-width="3613" height="256" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNcEnrTL8y8jRgcjCLl7K9yg5LFM-wcVH8R5pWSUe-eXC3NgqJw5jvUOBrtfLMj8DdOIO4slOdATjBik6jDQJdbY7NE3lqmBOmfIn3GiybbRQQ5M2cv6LuBjLdbFczyx56fCfCBGhW74bNWWApYOahCH6yZoJN4lvrp-jASvW_GKSSnvGbe3NOiohT/w640-h256/IMG_6533%20copy.jpg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The slide valve is a complex piece of engineering (setting hole indicated)</span><br /></td></tr></tbody></table></span><span style="font-family: arial;"><span style="font-size: small;"><br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"></span></div><div style="text-align: justify;"><span style="font-family: arial;"></span></div><div style="text-align: justify;"><span style="font-family: arial;"></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVIfoxmPogxuRv8ERbUDEi7BT7cSH1DdiBsyF7gHqzt90ICBiZBtmn3KgtK3w-0m2cxUJyT-U9OJ4_V7xCXYd5X1BMLFYWrDxEfwruGW6X8krIEbe_n50We1r5SNKWGHeawWoZfPtHAW3gdDUv21v3X2pxl67EXab_1Uq43IK2vywC0k5KJTw6SI6H/s4032/IMG_6648%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVIfoxmPogxuRv8ERbUDEi7BT7cSH1DdiBsyF7gHqzt90ICBiZBtmn3KgtK3w-0m2cxUJyT-U9OJ4_V7xCXYd5X1BMLFYWrDxEfwruGW6X8krIEbe_n50We1r5SNKWGHeawWoZfPtHAW3gdDUv21v3X2pxl67EXab_1Uq43IK2vywC0k5KJTw6SI6H/w300-h400/IMG_6648%20copy.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Setting pin correctly located</span><br /></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">The setting hole is on the underside of the gear brain, so once confident that I had the slide valve set in first gear position, I used a bt of copper wire to keep my pin in place.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHlHi_2PJdNBPJKvhyphenhyphen4mbzkxjapH3BsbWAFIAwnE5Oe8yDMcrx2suRV5NvE5l1KysG4_rGEXJjvtjyci99zxXAlL544_SztimF6tPrFymPLViP1k5l4dlDjkzzMH3HOtnhMkuRbwe7_oz2qkbaixmKPrT6CQU7SokWdR_4kIoguw0-euHcygcw5wZ6/s4032/IMG_6652%20copy.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHlHi_2PJdNBPJKvhyphenhyphen4mbzkxjapH3BsbWAFIAwnE5Oe8yDMcrx2suRV5NvE5l1KysG4_rGEXJjvtjyci99zxXAlL544_SztimF6tPrFymPLViP1k5l4dlDjkzzMH3HOtnhMkuRbwe7_oz2qkbaixmKPrT6CQU7SokWdR_4kIoguw0-euHcygcw5wZ6/w400-h300/IMG_6652%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: small;"><span style="font-size: x-small;"> I used some wire to stop the pin dropping out during fitting</span></span></span></td></tr></tbody></table> The gear brain bolts through a tunnel piece - that passes through the bulkhead - and onto the gear wand/ changer mechanism. I had already repainted and fitted the tunnel. </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAV9bcj5UAqdgmvKdQVblTumzvxUHzmcf1PkUWsqm3OIg3YJ9HkkNoPjjCE6cEUPy9nKHQZOzz6y-H51TtTOUWke8YriXu7HWPPAj3FZDqQGQDnFyI6NDL5DKeYYcP-RBr22QOXPYjjUTCzyp-V4A91s-YmvYDnGtGiDoTvpQNyTUbUiu9LIz_IAFv/s4032/IMG_5889.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAV9bcj5UAqdgmvKdQVblTumzvxUHzmcf1PkUWsqm3OIg3YJ9HkkNoPjjCE6cEUPy9nKHQZOzz6y-H51TtTOUWke8YriXu7HWPPAj3FZDqQGQDnFyI6NDL5DKeYYcP-RBr22QOXPYjjUTCzyp-V4A91s-YmvYDnGtGiDoTvpQNyTUbUiu9LIz_IAFv/w400-h300/IMG_5889.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The 'tunnel' piece being repainted.....</span><br /></td></tr></tbody></table>The gear wand had only
been loosely fitted to the dashboard shelf at this point.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAp-boGFGtUw6jdwsD491ouPZK_uAmDIgAWjsdyRMHePKoLMaDCCivnr3f3BBMyCX9_NJwW46EoZmV9XLYe65wTof6T65IshtNC0413H4Sq8sgl0l23dq5uiH1vfLaAXeuuv2CQ5qqH_J9OpbrR63tvv9NWU32XaZ6p2LvLbvNWRYTbmj_LhxfhuMe/s800/gearchange%20levers.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="601" data-original-width="800" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAp-boGFGtUw6jdwsD491ouPZK_uAmDIgAWjsdyRMHePKoLMaDCCivnr3f3BBMyCX9_NJwW46EoZmV9XLYe65wTof6T65IshtNC0413H4Sq8sgl0l23dq5uiH1vfLaAXeuuv2CQ5qqH_J9OpbrR63tvv9NWU32XaZ6p2LvLbvNWRYTbmj_LhxfhuMe/w400-h300/gearchange%20levers.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Gear 'wand' mechanisms (photo credit: Faullksy)</span><br /></td></tr></tbody></table>I had cleaned off the old grease that
had accumulated dust and dirt and re-greased it anew. I had cleaned up the
starter switch and contacts - making sure they were in good condition.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHjaydyz5eEpGg0vHtG-9NffNaTykzl5DuG3uqOp7V4_36uB9zXJfDQ9P1tlmuIdtaREzy5HYy0pAjZ9t7mHoutZVWapIwF9Z6YJeKlMZttsWIRHRkUnafjNVZo2xSuNjiBxe0rtI8S2xBJMdUVHj2thG54AI4CFyzsohUQRrBSokpV6xY3vgAk_b1/s4032/IMG_6157.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHjaydyz5eEpGg0vHtG-9NffNaTykzl5DuG3uqOp7V4_36uB9zXJfDQ9P1tlmuIdtaREzy5HYy0pAjZ9t7mHoutZVWapIwF9Z6YJeKlMZttsWIRHRkUnafjNVZo2xSuNjiBxe0rtI8S2xBJMdUVHj2thG54AI4CFyzsohUQRrBSokpV6xY3vgAk_b1/w300-h400/IMG_6157.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">I cleaned the gear selector (wand')</span><br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGzssdv6JaMFLE0G7xLUVUm0EHxbT74NoNPOpnk9YmBF_w4mrutfqYb9RTf3uiDie-gLLNwBrUUTtn3CyuIBBTEbSWZ0ZlKztpRdFxrfF_CW-w78nURlNq9AlXqgNzraP7D7R-H0Wl_cUfcJSwi_LHi5NVZ3q8vvrNuggobLnHh1ICZI8WZ7a1PPuo/s3264/IMG_0173.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGzssdv6JaMFLE0G7xLUVUm0EHxbT74NoNPOpnk9YmBF_w4mrutfqYb9RTf3uiDie-gLLNwBrUUTtn3CyuIBBTEbSWZ0ZlKztpRdFxrfF_CW-w78nURlNq9AlXqgNzraP7D7R-H0Wl_cUfcJSwi_LHi5NVZ3q8vvrNuggobLnHh1ICZI8WZ7a1PPuo/w300-h400/IMG_0173.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">I checked and cleaned the starter switch</span><br /></td></tr></tbody></table>Before presenting the gear brain, I hooked the end of the operating rod for the auxilary clutch to the auxilary clutch valve. Because of the hook end, and the diameter of the hole the rod passes through, it's not possibe to fit this rod after the brain has been fitted.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXd8nb2CBBUPSgLNQYlqKOwP_FHKCudo0H1_yL91Lq9Sprd4At8Ay1OL1uC1BdEoU8kjeUVgMRvqRRC8EDyrJEB_An5Z79yqj20PtH7WnighVa4wxe7rAO8quiZU1-d3UL_zutF_bxRuKofzx-KYDbP_cgFHQtViiHWBnXs8XAE3X7MpYdt2NpCczR/s4032/IMG_6640.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXd8nb2CBBUPSgLNQYlqKOwP_FHKCudo0H1_yL91Lq9Sprd4At8Ay1OL1uC1BdEoU8kjeUVgMRvqRRC8EDyrJEB_An5Z79yqj20PtH7WnighVa4wxe7rAO8quiZU1-d3UL_zutF_bxRuKofzx-KYDbP_cgFHQtViiHWBnXs8XAE3X7MpYdt2NpCczR/w400-h300/IMG_6640.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Hook on auxilary clutch control rod</span><br /></td></tr></tbody></table>I had my hands full with the next bits as you need to work on both sides of the bulkhead at the same time. The operating rod for the auxilary clutch was threaded through the tunnel and through the trunion on the clutch lever.....</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgJePQNvLDSLPC4IJcCgn7WMIG38J_dp7N3yaVhiIJswJ8pwOxgUJHuaiFUs9m0QQnYiOU6vKAjqShcY7LTs0gvIFhnMpHV_strjTn7J92owZ8slpEkDyUHP2bUPlx3ea-8sA0vKfyZ6wS4k2DcGGMkWQOvUS5RxBziz-xUsJcw1pDH-nXoH1Id0oP/s4032/IMG_6641.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgJePQNvLDSLPC4IJcCgn7WMIG38J_dp7N3yaVhiIJswJ8pwOxgUJHuaiFUs9m0QQnYiOU6vKAjqShcY7LTs0gvIFhnMpHV_strjTn7J92owZ8slpEkDyUHP2bUPlx3ea-8sA0vKfyZ6wS4k2DcGGMkWQOvUS5RxBziz-xUsJcw1pDH-nXoH1Id0oP/w400-h300/IMG_6641.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Auxilary clutch control rod and trunion</span><br /></td></tr></tbody></table> .... at the same time that the slide valve of the brain was threaded onto the gear wand mechanism - hidden away inside the tunnel.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> The
brain is held in place by two bolts. The tips are pointed. There is a
reason for this! Once the brain is presented to the tunnel piece, it
becomes very difficult to locate the nuts on the bolts. Pointed bolts
helps to get the theads located. </span></span><span style="font-family: arial;"><span style="font-size: small;"> <br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg14bBYuzHXp3Q-mrX7TMBIjfcgBQIWaYQNJbmN45P_rJGbHMY4yJzFAhcMp9vM1-P_kx6ltavo32CiASiTO4WUvOu6ieaXPOHYBzUSW3lv3lvW6JsmktWp1XfuB06HNwbGn4awvesyPYLu8Ak1DJSZRoLtjiuirKKhg26c5Y13Hc4MVAsh6CIWTPFX/s3264/IMG_0175.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg14bBYuzHXp3Q-mrX7TMBIjfcgBQIWaYQNJbmN45P_rJGbHMY4yJzFAhcMp9vM1-P_kx6ltavo32CiASiTO4WUvOu6ieaXPOHYBzUSW3lv3lvW6JsmktWp1XfuB06HNwbGn4awvesyPYLu8Ak1DJSZRoLtjiuirKKhg26c5Y13Hc4MVAsh6CIWTPFX/w400-h300/IMG_0175.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Hard to see: the fixing bolts are hideen away deep in the tunnel</span><br /></td></tr></tbody></table>That's great in theory, but what you are battling is gravity: the nuts fall out of the socket before they reach the bolts. I used a little Blutak to hold the nuts in a socket on a long extension bar. </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;">With the gear brain bolted home, I tightened the bolts securing the gear wand to the dashboard shelf and 'tunnel' part.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf-pe3HtERrDLrnAsNX_THi93Lnhr9jqHYNbkgh5xif_VIDLU8Ns8h3f2i_zevrZCL3ktF8-Mp1yDzt6SkgQgkkCGuvWL1oTF7u9WK-kGrw-dOkBJhnjD3Ap3TvuKE6ZBdzZVFiQP3eX-sl1LOuHX4gKZRw0cRovGP5CWbX9M_ssIEAHY3IayAenvO/s3264/IMG_0182.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf-pe3HtERrDLrnAsNX_THi93Lnhr9jqHYNbkgh5xif_VIDLU8Ns8h3f2i_zevrZCL3ktF8-Mp1yDzt6SkgQgkkCGuvWL1oTF7u9WK-kGrw-dOkBJhnjD3Ap3TvuKE6ZBdzZVFiQP3eX-sl1LOuHX4gKZRw0cRovGP5CWbX9M_ssIEAHY3IayAenvO/w400-h300/IMG_0182.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Fixing for the gear wand mechanism</span><br /></td></tr></tbody></table><span style="font-size: small;">The special pin holds ther gear brain in 'first gear' position, and so the gear wand has to be in the same 'first gear' position too - before the bolts joining them together are tightened. I had to dig out the 'gate' from my dashboard top to remind myself where the first gear position was.....</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkHQEpQhukkB7XKcu3bpPaehx5q_3ojrfxr1l4Q9_zG5N9v2ZZzyMzh-_KAPlwFA8OoGWiKt51eNLplX2jxIK0XyQCJ5ML89h6Ht5bOz7UwH-CULcEL-zI7nUMgmA3yJlnlLcW8tPLxSDVEvlbhERUyArIBdO57buZsRL9tjiJ4EkRmNfpWwUJQQhl/s4032/IMG_6651%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkHQEpQhukkB7XKcu3bpPaehx5q_3ojrfxr1l4Q9_zG5N9v2ZZzyMzh-_KAPlwFA8OoGWiKt51eNLplX2jxIK0XyQCJ5ML89h6Ht5bOz7UwH-CULcEL-zI7nUMgmA3yJlnlLcW8tPLxSDVEvlbhERUyArIBdO57buZsRL9tjiJ4EkRmNfpWwUJQQhl/w400-h300/IMG_6651%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Working out 'first gear' position......<br /></span></td></tr></tbody></table><span style="font-size: x-small;"></span><span style="font-size: small;">With first gear selected, the two bolts joining the selector rod on the gear wand, to the slide valve on the gear brain were tightened from above and the special pin (tool 2429-T) was removed. </span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_3gb710y940QjbnGH13XgsM4X2imWKIzjmjFntD3aVgtJFurKLy2k7l3sME48IQfqZwkeRUtky_JxFk4Qs6gGAx200dWcKJ8KVxBziTVJ7V95NI9m68xmXHf4JTi1eX2Mk3IcHsBpt5ELYtEhKgYm5slgNq0H2koZU_UAOo_knHhZQP7hIn9Pf73O/s4032/IMG_6656%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_3gb710y940QjbnGH13XgsM4X2imWKIzjmjFntD3aVgtJFurKLy2k7l3sME48IQfqZwkeRUtky_JxFk4Qs6gGAx200dWcKJ8KVxBziTVJ7V95NI9m68xmXHf4JTi1eX2Mk3IcHsBpt5ELYtEhKgYm5slgNq0H2koZU_UAOo_knHhZQP7hIn9Pf73O/w300-h400/IMG_6656%20copy.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Access to the bolts to secure the selector<br /></span></td></tr></tbody></table></span><span style="font-size: small;">The last job was to set up the auxilary clutch lever and rod. The hooked rod (and so the auxilary clutch valve in the gear brain) are pushed FORWARD, and the little lever under the dash is pulled BACKWARDS. The square-headed screw on the trunion is then tightened to secure the rod.</span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPqmb5lYmKPsAMF4b05d57Q_1BHwPfTSXqud40nSH6DGRryusxVob-getWwIQaY8QwlE3HivDD3TzkcK_YGX-alVV6TMVa_4jwkrrdgXTF_JkXkxCptp7M-GiqjrbhbknMy-c7Xnuwp9L-wgO1BmFjLQmHRvfgpjfmXupVmAW1Q3_6ycSUrSc2iHMa/s4032/IMG_6642.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPqmb5lYmKPsAMF4b05d57Q_1BHwPfTSXqud40nSH6DGRryusxVob-getWwIQaY8QwlE3HivDD3TzkcK_YGX-alVV6TMVa_4jwkrrdgXTF_JkXkxCptp7M-GiqjrbhbknMy-c7Xnuwp9L-wgO1BmFjLQmHRvfgpjfmXupVmAW1Q3_6ycSUrSc2iHMa/w400-h300/IMG_6642.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The rod is pushed forward and the lever pulled back.....</span><br /></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-size: small;"> And that was it for now.</span></span></div><p style="text-align: left;"><br /></p>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-68704613204860230772023-04-20T14:06:00.001+00:002024-01-16T16:51:43.913+00:00Parking Brake Pedal<div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">This one had me scratching my head for a while.......</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4zTMzeEzeyTwI1LCLSz5uy3tGNvwKocCo_XPX5_YDBZ3izfXzW4jvwBDI_qI1FMYxAxlCHfCWcEX7Prb2ZXgim3R6ZYQ4kLAlr8F6gnsYWCwS87V1unyZ5Mf36t7FuPHwyB799h0HH264ERUpSA-noY4OGHOF8HTaP_jx73pFCaXOXATNceheGKAr/s4032/IMG_7827.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4zTMzeEzeyTwI1LCLSz5uy3tGNvwKocCo_XPX5_YDBZ3izfXzW4jvwBDI_qI1FMYxAxlCHfCWcEX7Prb2ZXgim3R6ZYQ4kLAlr8F6gnsYWCwS87V1unyZ5Mf36t7FuPHwyB799h0HH264ERUpSA-noY4OGHOF8HTaP_jx73pFCaXOXATNceheGKAr/w480-h640/IMG_7827.jpg" width="480" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The parking brake on my DS21</span><br /></td></tr></tbody></table>The parking brake on my DS is foot-operated and, over the years, the mechanism had begun to look a bit tired and was gummed up with grease and dust.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBCmZ_UtKafqYzRdH6L961Rhw5UTwyXPyZgGOXEFqspcPQtrJ8dCV3BjmBcBqoPy4iNSaYW4WUEGi9WfkNfWH_vZAwdQn47Zs2En3L2x6zud8aA26MkDrDLAC81y7vxxnS5st1lqxjuns7D0MKkl5Vb4BQ9k9QF2ktAA5Sfcqfic_aa5sMeb1TBYNQ/s3264/IMG_0719%20copy%202.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBCmZ_UtKafqYzRdH6L961Rhw5UTwyXPyZgGOXEFqspcPQtrJ8dCV3BjmBcBqoPy4iNSaYW4WUEGi9WfkNfWH_vZAwdQn47Zs2En3L2x6zud8aA26MkDrDLAC81y7vxxnS5st1lqxjuns7D0MKkl5Vb4BQ9k9QF2ktAA5Sfcqfic_aa5sMeb1TBYNQ/w300-h400/IMG_0719%20copy%202.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The parking brake was looking tired</span><br /></td></tr></tbody></table></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">The
pedal unit had been removed from the cabin a long time ago - mainly so
that the engine bay area was free of the cable - however it wasn't
until late 2022 that I turned my attention back to it. </span></span><span style="font-size: small;"><span style="font-family: arial;">The rust was only on the the edges and part of the surface, surface and all it really needed was a refresh. </span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1RIMKd0BbrqJNLsZkKNPuEFlVj-uUXmDTcd5Yx22dgEsKRWmg3WUxAGmQBrtPjWd6wvXHUlDVlPOmFsIqwwh72oHmDjZL4x-JfMWHJRLxku5vg3EiVf_TAgeAOJQtVvV0TsghagAnuzzzqBEeu7tRUsT_KXxSDr9MKrZ1SMNP7QKdM8ovdXbK7YBT/s4032/IMG_5496.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1RIMKd0BbrqJNLsZkKNPuEFlVj-uUXmDTcd5Yx22dgEsKRWmg3WUxAGmQBrtPjWd6wvXHUlDVlPOmFsIqwwh72oHmDjZL4x-JfMWHJRLxku5vg3EiVf_TAgeAOJQtVvV0TsghagAnuzzzqBEeu7tRUsT_KXxSDr9MKrZ1SMNP7QKdM8ovdXbK7YBT/w400-h300/IMG_5496.JPG" width="400" /></a></div>It just needed a re-spray. However it's made of several moving parts - so how to do that?</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTeVD1USZPduxVqYWApKyXamR5JBM4g24EtutVliizrj3bboXQtL6WBKMV0SiXyve80ljn83ZYUEVA1eTatM8OoZv80PFRVG_vOke9y1cNlpwGJ_cgj8H65TBViP6QcO6-GdXe-DlFjtz1TMItf0dVag20ovx1oiwHfkHuorRl7s97fBimte61e2nO/s4032/IMG_5478.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTeVD1USZPduxVqYWApKyXamR5JBM4g24EtutVliizrj3bboXQtL6WBKMV0SiXyve80ljn83ZYUEVA1eTatM8OoZv80PFRVG_vOke9y1cNlpwGJ_cgj8H65TBViP6QcO6-GdXe-DlFjtz1TMItf0dVag20ovx1oiwHfkHuorRl7s97fBimte61e2nO/w300-h400/IMG_5478.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">My 'tired' brake unit having a lie down......</span><br /></td></tr></tbody></table>'Citrothello'
carries out comprehensive dismantling and reassembly. You can find that
on his website <a href="https://citrothello.net/blog/remise-en-etat-frein-a-main-ds/" target="_blank">HERE</a>. He dismantles the units and re-plates
some parts to make them shiny again.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVjowHuHzQgUqVGWlFEvvLaFMo_Hgl2HzC9P43vrOyjS_pAasUDfsRgzBd9PLi0DbXrRYBmj8LD_V1tl2bK2Ubbe_xTbU-cEB-S6nh7lyGUZfZs5yvPBQv9gWBWFXlFrEocViYBrTH7ehPYwU4CbQlXfKF8LNyLPUmDSxAm0hkECYCGko-6AxBXto9/s1002/CITROTHELLO%201.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="749" data-original-width="1002" height="299" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVjowHuHzQgUqVGWlFEvvLaFMo_Hgl2HzC9P43vrOyjS_pAasUDfsRgzBd9PLi0DbXrRYBmj8LD_V1tl2bK2Ubbe_xTbU-cEB-S6nh7lyGUZfZs5yvPBQv9gWBWFXlFrEocViYBrTH7ehPYwU4CbQlXfKF8LNyLPUmDSxAm0hkECYCGko-6AxBXto9/w400-h299/CITROTHELLO%201.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">'Citrothello' carries out a thorough restoration to 'as new' finish</span><br /></td></tr></tbody></table><br /></span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtEsrHKJbbXAz3UFre_Te8coqwJ3Qseghmq8ubPvOm140GsTyyjNb_X3f8ZeFfbXOSN2mxCCADFnUqhMZFV26M5X5kWwL1wSXAMyqiBXgx7Wo0CWMH17ZASwRh0KPOskHxqvGh4scqdAU-AexL18Fwu_q4AkePyK8kIPJUlPQ6k4tLsCEWot6JnlQ8/s879/Citrothello%202.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="653" data-original-width="879" height="297" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtEsrHKJbbXAz3UFre_Te8coqwJ3Qseghmq8ubPvOm140GsTyyjNb_X3f8ZeFfbXOSN2mxCCADFnUqhMZFV26M5X5kWwL1wSXAMyqiBXgx7Wo0CWMH17ZASwRh0KPOskHxqvGh4scqdAU-AexL18Fwu_q4AkePyK8kIPJUlPQ6k4tLsCEWot6JnlQ8/w400-h297/Citrothello%202.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Parts are removed for zinc plating</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">However
the unit is rivetted together, and while dismantling held no fears for me, I did regard it as 'destructive'. I thought about reassembling with some clever two-part 'binding screws'.......</span></span><div style="text-align: left;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdDv3iMexCK6bQxPgg0A0x3K1s3B6frUXSLDYX4famgXc2MrsBKrtqgqlwItmR6iHbQdW8jvAudlNzI8NoKIS5zvBfC5ErOxKp4Wvxh-py1gt1EPnqFsUp5wO_3XUZgkDRv-FP6eGK_Q2PRhVvDb3AZ_Ek1Ha6ax0NQ-BjAJWih-WGRBEfrmunb3VA/s1402/for%20parking%20brake.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="805" data-original-width="1402" height="230" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdDv3iMexCK6bQxPgg0A0x3K1s3B6frUXSLDYX4famgXc2MrsBKrtqgqlwItmR6iHbQdW8jvAudlNzI8NoKIS5zvBfC5ErOxKp4Wvxh-py1gt1EPnqFsUp5wO_3XUZgkDRv-FP6eGK_Q2PRhVvDb3AZ_Ek1Ha6ax0NQ-BjAJWih-WGRBEfrmunb3VA/w400-h230/for%20parking%20brake.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;"><span style="font-family: arial;">I considered binding screws to replace the rivets</span><br /></span></td></tr></tbody></table></span><span style="font-size: small;"><span style="font-family: arial;">.....but - as with the spirit of the whole restoration - decided to dismantle as little as possible. All I
wanted to do was to give it a quick tidy up and some fresh paint. </span></span></div></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">Removing the large split pin and bushes that holds the brake cable was straightforward. </span></span><span style="font-size: small;"><span style="font-family: arial;">I had already ordered a new replacement pin from Dirk Sassens earlier in the year (his part number 8169) </span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0Kc2Is7lEMpfci4ZN3USITUQ9GTXW4VBhTQrweoJPfAJS-gFyPmRwTNUfSzgchAp_5tcK3QFROpzELEfXFB2zL1RPOs1BFyEQUsF1u4DzhECnur5SRJLdheL9z-94iHbEFGHd53_RpXcp5o7TY5ot__Zr-0a80VcnnCopg-yKPjWxBTCyLZ2QsSJU/s4032/IMG_5499.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0Kc2Is7lEMpfci4ZN3USITUQ9GTXW4VBhTQrweoJPfAJS-gFyPmRwTNUfSzgchAp_5tcK3QFROpzELEfXFB2zL1RPOs1BFyEQUsF1u4DzhECnur5SRJLdheL9z-94iHbEFGHd53_RpXcp5o7TY5ot__Zr-0a80VcnnCopg-yKPjWxBTCyLZ2QsSJU/w300-h400/IMG_5499.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A split pin holds the parking brake cable</span><br /></td></tr></tbody></table><br /></span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaGSM_o1Q9KJFQ502-y65V_6O-lvsjxXanM4WedlujFCC6AESniAiIl8mvhSjqyfshQI0OLFl9t_7HjOcPyvkXwXI-gw8HINY8uQCE_CUSEPDXaIXo0kq5LdK5Q1-4aCRcLHHZ0K51cRcqyYGCP3lMqeJriQTAgPx6Ny5HGCJdtmP1i4QG_Og1dnjS/s4032/IMG_5502.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaGSM_o1Q9KJFQ502-y65V_6O-lvsjxXanM4WedlujFCC6AESniAiIl8mvhSjqyfshQI0OLFl9t_7HjOcPyvkXwXI-gw8HINY8uQCE_CUSEPDXaIXo0kq5LdK5Q1-4aCRcLHHZ0K51cRcqyYGCP3lMqeJriQTAgPx6Ny5HGCJdtmP1i4QG_Og1dnjS/w400-h300/IMG_5502.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Removing the split pin.......<br /></span></td></tr></tbody></table></span><span style="font-size: x-small;"><br /></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPm6cUMDOAWe1HJmTlr-KOzKrJvlhnu2vLiw1_kUz29NH6jhvZcrt1I8qbC9VDapFdi7uiJ2XQNr6YaZVOW_60t8BObkkGJIJJjxyorXYdm2ZQsbBkcRCG94oZPEYeYQayrgrwn7rOYB7b8vt8FVNV8XDf6RF-mAEPphzyiIW5ZMasyhx-qmkd_msF/s4032/IMG_5503.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPm6cUMDOAWe1HJmTlr-KOzKrJvlhnu2vLiw1_kUz29NH6jhvZcrt1I8qbC9VDapFdi7uiJ2XQNr6YaZVOW_60t8BObkkGJIJJjxyorXYdm2ZQsbBkcRCG94oZPEYeYQayrgrwn7rOYB7b8vt8FVNV8XDf6RF-mAEPphzyiIW5ZMasyhx-qmkd_msF/w400-h300/IMG_5503.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">.....allows the cable to be withdrawn.</span><br /></td></tr></tbody></table></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">The parking brake is operated by a foot pedal and then locked in the 'on' position using a lever. That lever has it's own locking knob (and and also a litle rubber-tipped locking knib!). The knob is pulled against the resistance of a spring and locked into place in a plastic 'gate' to hold the hand brake on or off. The small knib inside the gate locks the knob into position to prevent it accidentally being released.</span></span><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: left;"><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8JN4PLfW9xAr3PTm8kQx1JSt4jWewOma6sECe67OwZFTf8BR_9N8emTQE6As6K2nLsXtofb5QauIsqt15RR0NMN0NowYiEe07WTa_34Zu7tij-vYq8Iol_MtOA6hy_ZjKiE4hn-3d-j_KjpW-8XSKJZNs_SaXDG6bevsSeHVCZjrILBLX59prhnzj/s4032/IMG_5847.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8JN4PLfW9xAr3PTm8kQx1JSt4jWewOma6sECe67OwZFTf8BR_9N8emTQE6As6K2nLsXtofb5QauIsqt15RR0NMN0NowYiEe07WTa_34Zu7tij-vYq8Iol_MtOA6hy_ZjKiE4hn-3d-j_KjpW-8XSKJZNs_SaXDG6bevsSeHVCZjrILBLX59prhnzj/w400-h300/IMG_5847.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The locking knob......</span><br /></td></tr></tbody></table><br /></span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihe-N6FGTvjdyW3c8WGtGMP4Y1iyrXhofL14HwV8YbaST8iwz9aDcpKx-H1nWWV4iTnM2LGp4S5X43CokBKhT_NLlmaJ4mlfEYWhiSxKwEKk9tqBBQX9ygTiO8Yzp0nbiw46983CuglpDuerNBihb4_EIIbXX-ZF1g6PUZnLtZZ_E2okmCUzcQSOPl/s4032/IMG_5846.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihe-N6FGTvjdyW3c8WGtGMP4Y1iyrXhofL14HwV8YbaST8iwz9aDcpKx-H1nWWV4iTnM2LGp4S5X43CokBKhT_NLlmaJ4mlfEYWhiSxKwEKk9tqBBQX9ygTiO8Yzp0nbiw46983CuglpDuerNBihb4_EIIbXX-ZF1g6PUZnLtZZ_E2okmCUzcQSOPl/w400-h300/IMG_5846.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">.....is 'spring loaded' against the plastic gate.</span></span><br /></td></tr></tbody></table></span><span style="font-size: small;"><span style="font-family: arial;">To paint the metal body up, I would need to remove the plastic gate and knib. </span></span><span style="font-size: small;"><span style="font-family: arial;">The platic gate is simply held on by a few screws. </span><span style="font-size: small;"><span style="font-family: arial;">But
first I would need to remove the plastic knob.</span></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-size: small;"><span style="font-family: arial;">And that's where my
problems and delays began......I couldn't work out how to remove it! </span></span></span><span style="font-size: small;"><span style="font-family: arial;">My car is a 1968 model and the design of the locking knob is ornate -
reflecting the design of the knobs on the dashboard - and is specific to
the</span></span><span style="font-size: small;"><span style="font-family: arial;"> 1968 year</span></span><span style="font-size: small;"><span style="font-family: arial;">.<br /></span></span><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5lVcmzJfkXYO8osT1ZRd-iDscleOkhT7pFBaqpSqj5p-PFHEwq7MEie48OHleinTRFZu-8fW_iezHNrsYEcPeiWlrBfe3PRVuPXmb2hOGfZVMIiQC3mOJ2qDC4YLYV76wj3InFpaVbO_oJC13R5rmOFGV1ykOqfLO-Sfzff7qdDbEvxAMz5Lx-sqR/s4032/IMG_5848.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5lVcmzJfkXYO8osT1ZRd-iDscleOkhT7pFBaqpSqj5p-PFHEwq7MEie48OHleinTRFZu-8fW_iezHNrsYEcPeiWlrBfe3PRVuPXmb2hOGfZVMIiQC3mOJ2qDC4YLYV76wj3InFpaVbO_oJC13R5rmOFGV1ykOqfLO-Sfzff7qdDbEvxAMz5Lx-sqR/w300-h400/IMG_5848.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The design of the knob matches the dashboard buttons</span><br /></td></tr></tbody></table></span></span><span style="font-size: small;"><span style="font-size: small;"><span style="font-family: arial;">The </span></span></span><span style="font-size: small;"><span style="font-family: arial;">parts book shows the 1968 and post-68 designs and shows a hole where a pin or rivet would hold the knob on. </span></span><span style="font-size: small;"><span style="font-family: arial;">Parts 10 (ringed) and 13 were for the 1968 model year only. After that, part 10 (not ringed) and 14 were fitted. </span></span></div></div></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPqj2DKVeNRNiyD5ui8NEnwCUntr_3dBsFz3k1qc6_YGqfNKbETbEalseN4qd9aFOFblEIXt3LbpDTuGnSyUfYFKBvXlOsLyQpzqrW7FIejHAH_yFba9fKhyphenhyphenGIjBtwtRD7vUd3G5vJ-Kjr2DKd5xBSkCCb5xoTJG_pbuaK9qCyzlsese2a5ko-Z79C/s784/parking%20brake%20pin%20location.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="447" data-original-width="784" height="365" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPqj2DKVeNRNiyD5ui8NEnwCUntr_3dBsFz3k1qc6_YGqfNKbETbEalseN4qd9aFOFblEIXt3LbpDTuGnSyUfYFKBvXlOsLyQpzqrW7FIejHAH_yFba9fKhyphenhyphenGIjBtwtRD7vUd3G5vJ-Kjr2DKd5xBSkCCb5xoTJG_pbuaK9qCyzlsese2a5ko-Z79C/w640-h365/parking%20brake%20pin%20location.jpg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Parts book extract showing a pin hole for a fixing<br /></span></td></tr></tbody></table>I tried to understand how the mechanism might work: from the parts it looked as though the rod (part 18) was inserted through the knob (part 10) slightly compressing spring (part 18) as it did so. Part 18 was then held in place in the locking arm with a pin through it and the locking arm at point '?' - keeping the spring inside compressed. A cap (part 13 or 14) covered the hole in the knob where part 18 passed through.... I reasoned that knob 10 could be pulled - compressing the spring further - but because part 18 was (split) pinned in place, the spring would cause the knob to spring back once you let go. <br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">The problem was that there was no hole on my locking arm? There were marks that looked a bit like a closed up hole (where a pin or rivet might be/ might have been) but - from studying photos of other knobs - it didn't seem to be quite where I expected a hole and pin to be. </span></span><span style="font-family: arial; font-size: small;">And they were off-centre.</span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5OYHdePERC9cdVUvEJD1BaoVS5g99V7Ecc8BVKyjwACBdYajWIMaeDXmYUuj5_wJlnUJf-JsKnPGTccX0I4UVLkKUYk4z5l-1mQrERdPUGYPnB9Z_XM-tp9Q4R0k1e6LHv8aeG0NzeWovs5QyH8gCAwUDMh4NLgD_Kcr_iYtXEO7Wg7aBrBQChgbA/s4032/IMG_5628%20copy%202.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5OYHdePERC9cdVUvEJD1BaoVS5g99V7Ecc8BVKyjwACBdYajWIMaeDXmYUuj5_wJlnUJf-JsKnPGTccX0I4UVLkKUYk4z5l-1mQrERdPUGYPnB9Z_XM-tp9Q4R0k1e6LHv8aeG0NzeWovs5QyH8gCAwUDMh4NLgD_Kcr_iYtXEO7Wg7aBrBQChgbA/w400-h300/IMG_5628%20copy%202.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Despite what you might think you see - no signs of a pin hole. Or rivet...</span></span><br /></td></tr></tbody></table><p><span style="font-size: small;"><span style="font-family: arial;">I started playing detective</span></span><span style="font-size: small;"><span style="font-family: arial;">: part
11 (a spring) and part 18 (an inner shaft) were common to both years.
You can clearly see the pin hole in part 18 and where it fits inside the
arm (shown as '?'). There is no part or part number for any kind of pin or rivet. The length of part 18 changed for the 1968 model
year - meaning any pin hole though it may correspond to a different '?'
spot on the arm.</span></span></p><div style="text-align: left;"><span style="font-family: arial; font-size: small;">I</span><span style="font-size: small;"><span style="font-family: arial;"> asked far and wide and sought out other photos - especially from other people that I knew had 1968 cars. I raised questions on 'Aussiefrogs' - the Australian Citroen forum</span></span><span style="font-size: small;"><span style="font-family: arial;">.....</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh98aiPj7oHoROW_-FnQYZJGYDI07vw9zSYYw0Hbnp4w3XVap13ELH1jwyLUZzdPijIgLEiJxfXsoJaYf4MVXBSbEjJbPh2vAYhVXP5GzU35P3uh4ZIbw_EOE_he3mPPj71xDdFzQXJ7CxbeOoKIula_ZGSAEhPhuvCsq_IwZqGBEvis5imvOVXmPGl/s1164/Faulksy_1970_RHD%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1164" data-original-width="828" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh98aiPj7oHoROW_-FnQYZJGYDI07vw9zSYYw0Hbnp4w3XVap13ELH1jwyLUZzdPijIgLEiJxfXsoJaYf4MVXBSbEjJbPh2vAYhVXP5GzU35P3uh4ZIbw_EOE_he3mPPj71xDdFzQXJ7CxbeOoKIula_ZGSAEhPhuvCsq_IwZqGBEvis5imvOVXmPGl/w285-h400/Faulksy_1970_RHD%20copy.jpg" width="285" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Arrow shows a split pin (photo credit: Faulksy)</span><br /></td></tr></tbody></table><br /></span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEic6AwpjdqcYWRwrWYwvlyj1cB2XhFzvLK3YWYinFxHMHOLO2QzUPmUSaGbLY1yvmg7jniF-t4zAfdSaQTZjycT1ykzJsqnOHjfrzSKdWy0NPEY-FzslPLe5er11LfalRYMaNzurMI6mfuE2_dgnClLruNkMx4acsHDkXF00p6ofrVoQOvRGagKa0iP/s2048/faulksy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1536" data-original-width="2048" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEic6AwpjdqcYWRwrWYwvlyj1cB2XhFzvLK3YWYinFxHMHOLO2QzUPmUSaGbLY1yvmg7jniF-t4zAfdSaQTZjycT1ykzJsqnOHjfrzSKdWy0NPEY-FzslPLe5er11LfalRYMaNzurMI6mfuE2_dgnClLruNkMx4acsHDkXF00p6ofrVoQOvRGagKa0iP/w400-h300/faulksy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Split pin hole (photo credit: Faulksy)</span><br /></td></tr></tbody></table></span><span style="font-size: small;"><span style="font-family: arial;">As they both have LHD 1968 cars like mine, I</span></span><span style="font-size: small;"><span style="font-family: arial;"> asked Graham Hersey in the UK and </span></span><span style="font-size: small;"><span style="font-family: arial;">and Stefano Orio in Italy. They were very helpful but I almost wish I hadn't asked - as </span></span><span style="font-size: small;"><span style="font-family: arial;">I got mixed and confusing answers: one 1968 car had a pin through the brake arm, the other did not!</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLgPJmPI5zb24PHvhkoojHYzuXYIvNEwxLL79klWocxSGwLftkc6Q5B9hLL4SZ-w-pLIPDRYsw5sZ3zwByZT5O-HiCe3MR1ouu1G_Rok2u4VEyGdww5MXe4a09QczGNTl_WZ4WRojyjeHHBSK1AWy9vNs5iB0M6eVxjp9R-f41Ju_Vr_KNPAXOtjsJ/s640/43E6A1F8-EEAB-4778-BC7A-D615642FFD12.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="640" data-original-width="480" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLgPJmPI5zb24PHvhkoojHYzuXYIvNEwxLL79klWocxSGwLftkc6Q5B9hLL4SZ-w-pLIPDRYsw5sZ3zwByZT5O-HiCe3MR1ouu1G_Rok2u4VEyGdww5MXe4a09QczGNTl_WZ4WRojyjeHHBSK1AWy9vNs5iB0M6eVxjp9R-f41Ju_Vr_KNPAXOtjsJ/w300-h400/43E6A1F8-EEAB-4778-BC7A-D615642FFD12.jpeg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Same knob, no split pin (photo credt: Graham Hersey)</span><br /></td></tr></tbody></table><br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZ2s2m5sY5Qct3cyF17jh5fvoTJNpfE-6j4D9mLyhCjuohIigSsdJY6MosAugcxgA4Ne0WWtj9rNwEWOZDRpZbTgopf-lPzEMP4oZp4tUgJ2UB0T6c3U63wpuQNBM3hwQtHVAtuKGEuyHCPGQmrj6Q8RlNVGaraDPpEdig6kJc2sDPwxtF_N_LCxFw/s2048/318059582_862315338238323_6001340781660637087_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2048" data-original-width="1152" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZ2s2m5sY5Qct3cyF17jh5fvoTJNpfE-6j4D9mLyhCjuohIigSsdJY6MosAugcxgA4Ne0WWtj9rNwEWOZDRpZbTgopf-lPzEMP4oZp4tUgJ2UB0T6c3U63wpuQNBM3hwQtHVAtuKGEuyHCPGQmrj6Q8RlNVGaraDPpEdig6kJc2sDPwxtF_N_LCxFw/w225-h400/318059582_862315338238323_6001340781660637087_n.jpg" width="225" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Same knob - but a split pin!! (photo: Stefano Orio)</span><br /></td></tr></tbody></table></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">I was getting nowhere and still couldn't remove the knob. While I sought advice, I cleaned up the old brake mechanism, but couldn't do much more. With the knob and knib still attached, there was only so much cleaning I could do. </span></span><br /></div><div style="text-align: left;"><div style="text-align: left;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwcGv2rCNacyfOiDztsf17DTjr7blGBcMK4NaobC_EMu1jaAdof_fNbSXTqnEdixdVLWJY49iVTLes4eCWofSH69N4xG_YSC8yGQy8wOwrMeg-VaFzkt249-ackbg-99ROqlN3DjDbmdsurFm_Yky2iDubzKPrdrhWembakj7pK2_7hM1mRYy_f7NP/s4032/IMG_5507.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwcGv2rCNacyfOiDztsf17DTjr7blGBcMK4NaobC_EMu1jaAdof_fNbSXTqnEdixdVLWJY49iVTLes4eCWofSH69N4xG_YSC8yGQy8wOwrMeg-VaFzkt249-ackbg-99ROqlN3DjDbmdsurFm_Yky2iDubzKPrdrhWembakj7pK2_7hM1mRYy_f7NP/w400-h300/IMG_5507.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Weld marks on the arm</span></span><br /></td></tr></tbody></table></span><span style="font-size: small;"><span style="font-family: arial;">I recall seeing that one
of the European suppliers - Dirk Sassens - sold secondhand knobs off
the brakes. How did they get them off? And how is a buyer meant to fit
them? I sent an email asking these questions. Using Google translate it
went like this.....</span></span><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: left;"><i><span style="font-family: arial; font-size: small;"><span></span></span></i><div style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; caret-color: rgb(0, 0, 0); color: black; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: left; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><i><span style="font-size: small;"><span style="font-family: arial;">Hallo Uwe</span></span></i></div><div style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; caret-color: rgb(0, 0, 0); color: black; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: left; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><i><span style="font-size: small;"><span style="font-family: arial;">Kann
ich bitte technische DS-Beratung haben? Weißt du bitte, wie man diese
spezielle Art von Pallas-Knopf entfernt? (Pallas betatigungsknopf
1965-1968). Steckt irgendwo ein Stift durch die Welle? Oder versteckt
sich hinter dem Chromeinsatz eine Schraube und Mutter für die
Feststellbremse? (Ihre Teilenummer 6734). Vielleicht weiß jemand bei
Sassen wie?</span></span></i></div><div style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; caret-color: rgb(0, 0, 0); color: black; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: left; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><i><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></i></div><div style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; caret-color: rgb(0, 0, 0); color: black; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: left; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><i><span style="font-size: small;"><span style="font-family: arial;">Vielen Dank</span></span></i></div><div style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; caret-color: rgb(0, 0, 0); color: black; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: left; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><i><span style="font-size: small;"><span style="font-family: arial;">Paul</span></span></i></div></div><div style="text-align: left;"><i><span style="font-family: arial; font-size: small;"><span> </span></span></i></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">To
my surprise - I got a phonecall back from Germany! I was really
grateful that Sassens had bothered to call me - but they couldn't
really help. I was told that there should be a split pin hidden away
there somewhere......<br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span><span style="font-size: small;"><span style="font-family: arial;">Citrothello's
website includes some handy photos on rebuilding the parking brake
mechanism - including one showing a rivet being removed from a later
'long arm' 70s DS parking brake. <br /></span></span><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDbTnqivM0uOvfyAoy7GPLlFxCoIfUqg2eqAqpTFC9Zxu08qjlZelvWJa56gbwZjAq_XDLfOFNizPeige5KwVzu1yw_DXkd7VYxd4fnT1wtLTWah7Td3TI4KnRL-b88j__Tt9ARziZ6fA4FEnk7WrW2-z8FF5pil7pV-Is1w8PtCYGCfB4D6qgFBYi/s932/citrothello%203.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="672" data-original-width="932" height="289" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDbTnqivM0uOvfyAoy7GPLlFxCoIfUqg2eqAqpTFC9Zxu08qjlZelvWJa56gbwZjAq_XDLfOFNizPeige5KwVzu1yw_DXkd7VYxd4fnT1wtLTWah7Td3TI4KnRL-b88j__Tt9ARziZ6fA4FEnk7WrW2-z8FF5pil7pV-Is1w8PtCYGCfB4D6qgFBYi/w400-h289/citrothello%203.jpeg" width="400" /></a></div>He
clearly knew how to remove the knobs. Surely he had also rebuilt
earlier brake mechanisms? Surely he knew how to dismantle them? In
desperation I emailed him but heard nothing back.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">I really wanted an end to this saga now as I was sick of having the thing laying around the workshop. I got to the point where I considered cutting the unit open - just to see how the damn thing was put together - then buying a different unit from elsewhere. I let that thought pass and busied myself with other jobs while I waited for inspiration.<br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">Before long I had a backlog of things I wanted to paint up and so added the brake mechanism to them. So, with some carefull cleaning and even more careful masking, I gave the mechanism a new coat of paint. I wrapped a platic bag over the knob and sealed it with a zip tie - which also held the knob against its spring - meaning could paint more of the locking arm. <br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioTLcop547KlPt37rZ4HK4jrlhT1d__PSB19yjn_wWeNPH6ncyviaS81XLANlHWdHjhkTtw5d9eRke2p4DRrOW-qfj1qMPU8genarDd2Z2JPXvaoPjcmAsJynPQkZ-wDRp7VZxwGN7y5Vg04CF2hlS_lt5a38nuj05ASZErMDAArzPGKFbevpy8xKS/s3024/parking%20brake_painting.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioTLcop547KlPt37rZ4HK4jrlhT1d__PSB19yjn_wWeNPH6ncyviaS81XLANlHWdHjhkTtw5d9eRke2p4DRrOW-qfj1qMPU8genarDd2Z2JPXvaoPjcmAsJynPQkZ-wDRp7VZxwGN7y5Vg04CF2hlS_lt5a38nuj05ASZErMDAArzPGKFbevpy8xKS/w400-h400/parking%20brake_painting.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Batch painting parts - including the parking brake mechanism</span></span><br /></td></tr></tbody></table><br /></span><span style="font-size: small;"><span style="font-family: arial;">It actually came out very well - just how I wanted it too, though I still felt a little crest-fallen as I was sure I had missed some obvious trick for remo</span></span><span style="font-size: small;"><span style="font-family: arial;">ving that knob.<br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">Shortly after this - one evening last month - and quite by chance, I stumbled across a Citroen 'Note Technique' ('technical note') that covered the brake pedal - note number 129 from November 1967. And here it is.</span></span></div></div></div><div style="text-align: left;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMYwbBzIy1NgKMfr933PC-DS7K2YXsKokHtw8Skz5tsaQcmqP3-DJ8V-AxbZnGE-Yd8Ey7A4OM0yZ3K_efgqut5LWZhnZCwQbVy_29kYQu-YQmz1ah4ZmNAbHX2I7DlpZOSxA69IEWqZ5zqyLB3hkHqLv0SFv_jDUpJSiTmcH-NiQt3UJ8IJoQuXE6/s836/NT129_brakes.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="836" data-original-width="663" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMYwbBzIy1NgKMfr933PC-DS7K2YXsKokHtw8Skz5tsaQcmqP3-DJ8V-AxbZnGE-Yd8Ey7A4OM0yZ3K_efgqut5LWZhnZCwQbVy_29kYQu-YQmz1ah4ZmNAbHX2I7DlpZOSxA69IEWqZ5zqyLB3hkHqLv0SFv_jDUpJSiTmcH-NiQt3UJ8IJoQuXE6/w508-h640/NT129_brakes.jpeg" width="508" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Citroen 'Note Technique 129'</span><br /></td></tr></tbody></table><span style="font-family: arial;"></span><span style="font-family: arial;">You can see that the photo on the front cover highlights a split pin. This note announced to garages that with effect from October 1967, the knob of the pedal unit was now removable. Meaning that - before that date - it <u>wasn't </u>removable. And there was <u>no</u> split pin! That changeover explained the mixed answers I got back from other D owners and from Sassens and how sassens were able to provide secondhand knobs - some were removable/ fittable. </span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"> </span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">The note went on to show the parts in the 'new' split pin version and they seemed to operate as I thought they had done Frustratingly, while the note explained how to assemble the new version, the removal/ disassembly instructions were also for this new version - not removing ones like mine.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8UvaY45Dj-wND8i40mOLBKRWRf1QrPoeqCv6PjCf0edFSkR5NQy7b9Ylqo8yNgRnwwDFML6GM4Fm-5uLS2YOXn0H2VOQrsVHqVQQm6ntzIdcZl6TedMocPG2PD2KI-lOfYLAWlSz-ukwP_XRKjvd2TfraP6q9kT76JFn5xQBtdgOAKQdGXEZhG9C6/s832/NT%20129_brakes%20Page%203.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="832" data-original-width="716" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8UvaY45Dj-wND8i40mOLBKRWRf1QrPoeqCv6PjCf0edFSkR5NQy7b9Ylqo8yNgRnwwDFML6GM4Fm-5uLS2YOXn0H2VOQrsVHqVQQm6ntzIdcZl6TedMocPG2PD2KI-lOfYLAWlSz-ukwP_XRKjvd2TfraP6q9kT76JFn5xQBtdgOAKQdGXEZhG9C6/w550-h640/NT%20129_brakes%20Page%203.jpeg" width="550" /></a></div><span style="font-family: arial;">Being the kind of person I am.... I looked at an earlier parts manual - manual 519 from 1966. This shows that the knob was similar/ same shape as the knob used after 1968. The difference in the diagram is that the knob is not shown exploded into it's component parts - it's not shown as removable from the locking arm.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYaQ5AsXke5lKkQBUUERiOBH7YBli2PkQyD_htkhcFQZFL0qqDMVOOiI5UQPUtkQ7z8xMRuWLypODU_3CzGIjz7bvqnnNi51P4eZea4FDXwc4ee2JCOENebFnjplHJjSFLSTzwpInvkp5v0jUoUuu5NIWfqlnsobUVHwCx1v90-sKoBKL0wWTkYr8C/s1068/Manual%20519%20diagram.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="775" data-original-width="1068" height="290" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYaQ5AsXke5lKkQBUUERiOBH7YBli2PkQyD_htkhcFQZFL0qqDMVOOiI5UQPUtkQ7z8xMRuWLypODU_3CzGIjz7bvqnnNi51P4eZea4FDXwc4ee2JCOENebFnjplHJjSFLSTzwpInvkp5v0jUoUuu5NIWfqlnsobUVHwCx1v90-sKoBKL0wWTkYr8C/w400-h290/Manual%20519%20diagram.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">The 1966 parts manual shows the knob as fixed to the arm</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">That would be consistent with the introduction of a split pin only from October 1967. I still have a query though: if the ornate style knob was introduced from October 1967, and the technical note says pins were fitted from October 1967 - then shouldn't ALL parking brakes with an ornate knob have a removal pin??</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">I really do need to put this to bed, and so the conclusion I've reached is that, as in other cases, there was a cross-over period before production settled down - so an ornate knob - but fixed.</span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;"><br /></span></span></div><div style="text-align: left;"><span style="font-size: small;"><span style="font-family: arial;">And another query: if the 'ornate-but-fixed' design is one of the earliest and pre-October 1967, then how did it come to be fitted to my Feb - April 1968 manufactured car? I guess Citroen have a stock of these parts made up for the production line and just reach into a bin and pull one out.....<br /></span></span></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-6698211535191298192023-04-16T06:57:00.002+00:002023-05-24T20:32:53.254+00:00Hydraulic Gear Selector - Strip Down and Overhaul (Part 2)<div style="text-align: justify;"><span style="font-family: arial; font-size: small;">In my last post I covered how I stripped down and rebuilt the main hydraulic gear selector - the 'gear brain'. In this 'part 2' post, I'll cover how I stripped and rebuilt the gearchange speed regulator. </span><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">It's a steel bodied, broadly cylindrical unit bolted on top of the gear brain. </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi61yJwoHl0de2FTLkftAJCEvgDaAUDBBzAOWFOlnAK7Tbes2j9jtR42Uf0l6ck9QfzvUWzlkbaTuwIx8YCrYgXcKg03Cy71BhAwuDoUu0dc0K2OhNeqSmXNZJzv2yuiLkX2Wxz5auUJQ26AKtZ6bCxNSGDeCTpIAqtJbbb1vxcg9XydHSuBFaPjw/s4032/IMG_6629.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi61yJwoHl0de2FTLkftAJCEvgDaAUDBBzAOWFOlnAK7Tbes2j9jtR42Uf0l6ck9QfzvUWzlkbaTuwIx8YCrYgXcKg03Cy71BhAwuDoUu0dc0K2OhNeqSmXNZJzv2yuiLkX2Wxz5auUJQ26AKtZ6bCxNSGDeCTpIAqtJbbb1vxcg9XydHSuBFaPjw/w400-h300/IMG_6629.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The gearchange speed regulator, on top of the 'gear brain'</span><br /></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">I'd got as far as seperating the regulator from the main 'gear brain'. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLb_RLMbrl9x5ilawRndVM_vA4gMnG2h_zk7Ke9HM0pndLOqJgAnOIWxgaSq7HNnNDxEIy5KD-chO8pnTLYr4u1aZBQk3_OUlmKVpaFm1X20rMcKXAryqT1ebYJqnPlp2F9gwJkCZ5VlxdhPx1RsqFz3zBxo7PhfRULQzNx0JvrtQYM57PyXxjrg/s4032/IMG_6507.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLb_RLMbrl9x5ilawRndVM_vA4gMnG2h_zk7Ke9HM0pndLOqJgAnOIWxgaSq7HNnNDxEIy5KD-chO8pnTLYr4u1aZBQk3_OUlmKVpaFm1X20rMcKXAryqT1ebYJqnPlp2F9gwJkCZ5VlxdhPx1RsqFz3zBxo7PhfRULQzNx0JvrtQYM57PyXxjrg/w300-h400/IMG_6507.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Gerachange speed regulator, on the gear brain</span><br /></td></tr></tbody></table> Dismantling and rebuilding involves giving the insides a good clean and replacing the rubber ring seals under the hex heads. <br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFw7nGHUqJjEaEd1iuz03gu6pDekTCmeFQ91KR1jIYKZOM04kd48wulxSju5o6k-KBoOLvYvr18k2NYYuYlrWrURlrYiLij5TYbjsS3UnvzCENKvmceg_11WUiGq3kvcOJAueIswx-tztZVlF0BFuD6BfDfytuqPEDhzXIwW6pH1xdzbow7C0ZIQ/s4032/IMG_6546%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFw7nGHUqJjEaEd1iuz03gu6pDekTCmeFQ91KR1jIYKZOM04kd48wulxSju5o6k-KBoOLvYvr18k2NYYuYlrWrURlrYiLij5TYbjsS3UnvzCENKvmceg_11WUiGq3kvcOJAueIswx-tztZVlF0BFuD6BfDfytuqPEDhzXIwW6pH1xdzbow7C0ZIQ/w400-h300/IMG_6546%20copy.jpg" width="400" /></a></div></span></span><span style="font-family: arial; font-size: small;">The gearchange speed regulator </span><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">was
introduced to deal with changes in fluid temperature and pressure that
would otherwise alter how the gear brain responded. Inside, it looks
like this.....</span></span><div style="text-align: justify;"><span style="font-size: small;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzTNGzqG9-gRokUvTD-FzNXI-lehFo2kukHSnwX0j0HPzbnBckoB81_iGaXqjDemLHo5QurlpDDBJrBHCqSkMbfolj_bmr5mVq5r4ZGvXBmmfxBd_cdMJ9kj6uNv7mxyYXZzX8948kc4_1znUa8IwuA0y4a-41AroNpRlFlDTlqpAv1Xd6niyIPQ/s866/viscosity%20regulator.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="704" data-original-width="866" height="520" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzTNGzqG9-gRokUvTD-FzNXI-lehFo2kukHSnwX0j0HPzbnBckoB81_iGaXqjDemLHo5QurlpDDBJrBHCqSkMbfolj_bmr5mVq5r4ZGvXBmmfxBd_cdMJ9kj6uNv7mxyYXZzX8948kc4_1znUa8IwuA0y4a-41AroNpRlFlDTlqpAv1Xd6niyIPQ/w640-h520/viscosity%20regulator.jpeg" width="640" /></a></div><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">The
numbers in brackets relate to the part numbers in the rebuild
instructions in English manual 518. But there is a 'but'....</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">At
this point I need to say that I love English language manual 518. As
well as a digital copy, I have two printed copies distributed around the
house. It contains loads of information not in later manual 814.</span></span><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> It's an essential companion if you carry out work on your DS. Here's the 'but'....as explained
in 'part 1', the gearchange rebuild instructions in English language manual 518
contain errors. And those errors are also in the section covering the
gearchange speed regulator. I think it was 'Faulksy' over in Australia that pointed this out.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">It's helpful to set up a couple of conventions so that it is clear what end of the regulator is being discussed. There is a large hex-headed screw at each end of the regulator body. </span></span><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">The body itself is a central cubid shape with a cylinder shape on each end. One cylinder end is long (the French rebuild instructions call this end 'a') and the other cylinder end is short (the French manual calls this end 'b'). The vast majority of work takes place through end 'a'. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">With the hex head of end 'a' removed, two pieces slide out - first a piston and then, after that, a spring.</span></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQ4Cpa87SgBam5wdfPsxBR5bs1PYNSEq-PyMr34zCG1YgAKTsgjrYKyrSDjwJmMgd8gHDotI1I_gCOaTbufJsL8R9bboHttnU901jM90qQtCLTIIoIyHKElXS-URFir8XsvfgT3h38QZZ2NSGc5YB5Vt_8EX8cD2Sre1liDH9pFlQSjJ_XKWBRMA/s4032/IMG_6547_copy2.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQ4Cpa87SgBam5wdfPsxBR5bs1PYNSEq-PyMr34zCG1YgAKTsgjrYKyrSDjwJmMgd8gHDotI1I_gCOaTbufJsL8R9bboHttnU901jM90qQtCLTIIoIyHKElXS-URFir8XsvfgT3h38QZZ2NSGc5YB5Vt_8EX8cD2Sre1liDH9pFlQSjJ_XKWBRMA/w400-h300/IMG_6547_copy2.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Initial disassembly of my regulator</span></span><br /></td></tr></tbody></table><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> Already this can become confusing if you' are being guided by manul 518. The text is correct, but the photo shows the parts laid out differently. Compare my insides to the (incorrect) photo in manual 518!</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBxzwiS0rV3v5gjFqJqPLGnqCveAh8QCtocDL_7SNqQm7fbtUUqljsrnkmSbHDdie65jIdAsZGaxEzsHGYalHvRP_g8k6KlVgH2W6b4_H3w9vrXsP-OtrzWxcBplIbsk4Rovuju5jCg0wbrRWij1XYWRd-P6KyDD7od7x1FG2DLF7oRZ3T2-mCuA/s653/incorrect%202.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="429" data-original-width="653" height="263" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBxzwiS0rV3v5gjFqJqPLGnqCveAh8QCtocDL_7SNqQm7fbtUUqljsrnkmSbHDdie65jIdAsZGaxEzsHGYalHvRP_g8k6KlVgH2W6b4_H3w9vrXsP-OtrzWxcBplIbsk4Rovuju5jCg0wbrRWij1XYWRd-P6KyDD7od7x1FG2DLF7oRZ3T2-mCuA/w400-h263/incorrect%202.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">WRONG: the incorrect photo in English manual 518</span></span><br /></td></tr></tbody></table><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">Not only does the photo in manual 518 that the spring comes out before the piston, but also the piston is the wrong way round relative the two ends of the regulator. By comparison, French manual 583 gets it right. (But note how the part numbers are different).<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwE5iL1T7dCMQxmYLblua3zOQ8QUbERtr0IFDHo-1jPQnU9rt5yyyMvhYkOzqfyFgUB2_3XEpa7DfaIDkUMeaEo3Afh8D1iO1IMC47eVi8FcNwtptweTHuxLno9Qzw6Rnu3rcNqoCysTesF1ern7bI5QuxDcFMygzVLsWHcRr-ixxXAvgDMehp1w/s719/correct%202.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="477" data-original-width="719" height="265" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwE5iL1T7dCMQxmYLblua3zOQ8QUbERtr0IFDHo-1jPQnU9rt5yyyMvhYkOzqfyFgUB2_3XEpa7DfaIDkUMeaEo3Afh8D1iO1IMC47eVi8FcNwtptweTHuxLno9Qzw6Rnu3rcNqoCysTesF1ern7bI5QuxDcFMygzVLsWHcRr-ixxXAvgDMehp1w/w400-h265/correct%202.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">RIGHT: the equivalent photo in French manual 583</span></span><br /></td></tr></tbody></table></span><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">The next task was to dismantle the piston to clean the parts inside.</span></span><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> </span></span><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">In doing so, I noticed that someone - presumably the machinist or maybe someone from quality control - had put their initial on my piston. Is this a fancy 'J'. Jacques? Just for a moment there was a smell of Gauloise in the air..........<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGdY5VcTSLgVIesP59_Ac44y7bZi8I9snAxbrimFEa-zKFvlsrWW3MQBeest0-m-ye11PX4tPaIok9v4qqN4rFZISoNbuLKFvW63baqbsX3KbI8mxFtYv-Railxtibs7qdet8B6ZZd6tw1mZJNRXOX_g2KxLOwsIoQ3WU6eUwTbXQLjK3XISFs9Q/s4032/IMG_6548.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGdY5VcTSLgVIesP59_Ac44y7bZi8I9snAxbrimFEa-zKFvlsrWW3MQBeest0-m-ye11PX4tPaIok9v4qqN4rFZISoNbuLKFvW63baqbsX3KbI8mxFtYv-Railxtibs7qdet8B6ZZd6tw1mZJNRXOX_g2KxLOwsIoQ3WU6eUwTbXQLjK3XISFs9Q/w400-h300/IMG_6548.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Signed with pride?</span><br /></td></tr></tbody></table></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">Access to the piston is gained from a slotted screw <u>in the end of the piston.</u> I emphasise this to draw a distinction between it and another 'slotted screw': behind the hex screw on end 'b' is a slotted adjuster and it should not be adjusted!<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizDO5tcSdBgeGKOS33mTZmEyHVlB70S-7idyGecJCLLtcbKMLY0cnB4rG_3Dj9H2fC7bsNnLgVG4TqGN8uhXyikwGEDKRNW-d3RvrAmlK-2IcmroADcjOq3CC9Uurzvl6xPvhBs6-SpxIhleaFioAPQxkUzHxl-sgcUVBIV9Kky7cE431wBr4hxg/s4032/IMG_6556.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizDO5tcSdBgeGKOS33mTZmEyHVlB70S-7idyGecJCLLtcbKMLY0cnB4rG_3Dj9H2fC7bsNnLgVG4TqGN8uhXyikwGEDKRNW-d3RvrAmlK-2IcmroADcjOq3CC9Uurzvl6xPvhBs6-SpxIhleaFioAPQxkUzHxl-sgcUVBIV9Kky7cE431wBr4hxg/w400-h300/IMG_6556.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Slotted screw in the regulator body. No - do not tinker!</span></td></tr></tbody></table></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">It's basically a variable 'stop' for the end of the spring. This is <u>factory set</u> for each unit and is not meant to be tampered with. Presumably there were slight variations in body engineering and spring strength and each unit is different. Manual 518 tells you not to alter it, but doesn't really make clear where it is.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">You might have bought a rebuild kit that contains replacement springs, and feel obliged to replace the spring in the the regulator - reasoning that the old spring might be tired and worn. I would advise against replacing it.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrDgROoFPL1vNMSb9apI6FgkDfyaIK5iWNOQttWPFPgnBEMq7Ed45lwsz5D1COs6N1G-JSWaNsv5nQgEKKhW4YcU9A4asGorkv6WHQOBEXq9ePatUGR37JUmutrrp7ZW8rQFNkwleNxxK7mAxFMwQBZYfKLKrSlp5CLLEV16BKNat5ybLKlV2jhw/s1382/kit.jpeg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="699" data-original-width="1382" height="203" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrDgROoFPL1vNMSb9apI6FgkDfyaIK5iWNOQttWPFPgnBEMq7Ed45lwsz5D1COs6N1G-JSWaNsv5nQgEKKhW4YcU9A4asGorkv6WHQOBEXq9ePatUGR37JUmutrrp7ZW8rQFNkwleNxxK7mAxFMwQBZYfKLKrSlp5CLLEV16BKNat5ybLKlV2jhw/w400-h203/kit.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Some rebuild kits contain replacement springs</span></td></tr></tbody></table></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">The spring itself is easily removed from end 'a' but think again before being tempted to replace it as there are no available measurements for setting a new spring up. So you will be no better off. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">Back to the piston from end 'a'. </span></span><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">Undoing the slotted screw in the piston end allows you to remove a surprising large number of very small (and easily lost) parts.</span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEix2Rqepb4SBIscC66UNqxg6afOX9rEFzZznxbYXfgc7toIXlqGuHwGSEN7QaU_YElR84kZruL70FRjGlyIXKz3xies26_I7brzgNXX3Zk51Km5iGm1ElNRNHuPDzn4NWbweZXcjfrxiVc4BAdmw7DHPYDfeoUbAnJuQtebJlpK6SSauSkzpI0QNw/s4032/IMG_6555.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEix2Rqepb4SBIscC66UNqxg6afOX9rEFzZznxbYXfgc7toIXlqGuHwGSEN7QaU_YElR84kZruL70FRjGlyIXKz3xies26_I7brzgNXX3Zk51Km5iGm1ElNRNHuPDzn4NWbweZXcjfrxiVc4BAdmw7DHPYDfeoUbAnJuQtebJlpK6SSauSkzpI0QNw/w400-h300/IMG_6555.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Slotted screw in the piston. yes - undo this...</span><br /></td></tr></tbody></table></span></span><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">These are a number of thin discs with small holes in them. You will also have a number of small steel rings. these are spacers for the discs. Last, but not least, you will also find a small circular gauze which lives at the far end of the piston.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEih0hMqnqJj5mLIBM5P_VolD1EjGlbZXHufE4EnoCWsC5RPE3bZ40DGvS5CLmNjAYdLrurT5Oyuq8xcePXfJR-dPtcy7fTQ9H42Gn4kZ-J7eFuQZIWJautrI44JcsbCMT0XPQ1aE9M1E6CvpkDYtZ7FC-AGH_fLo6VvI3dWjJq62JspPGRP_jzqxw/s4032/IMG_6554.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEih0hMqnqJj5mLIBM5P_VolD1EjGlbZXHufE4EnoCWsC5RPE3bZ40DGvS5CLmNjAYdLrurT5Oyuq8xcePXfJR-dPtcy7fTQ9H42Gn4kZ-J7eFuQZIWJautrI44JcsbCMT0XPQ1aE9M1E6CvpkDYtZ7FC-AGH_fLo6VvI3dWjJq62JspPGRP_jzqxw/w400-h300/IMG_6554.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Gauze in the piston end</span></span><br /></td></tr></tbody></table><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">In addition to the gauze, I removed 14 discs, 14 spacers and a washer. </span></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhK7ljgOVTYwIKh4h939Wd2OPBOuHjnxZ1HtfmahUQNBarfb9zy0V2mY5SL2_R3PxOzYs5tzvrBtvhJ1Syle_nlyxFqUTGnAX6TY7tYIWziZXq-NNi-l1xS1uK1ZS7IWE5RO-PeiKKaKUWfUitjeTfazIZOKQPpvfG2gsl0FjhFfZyeYkG_Wfx3Ug/s4032/IMG_6559.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhK7ljgOVTYwIKh4h939Wd2OPBOuHjnxZ1HtfmahUQNBarfb9zy0V2mY5SL2_R3PxOzYs5tzvrBtvhJ1Syle_nlyxFqUTGnAX6TY7tYIWziZXq-NNi-l1xS1uK1ZS7IWE5RO-PeiKKaKUWfUitjeTfazIZOKQPpvfG2gsl0FjhFfZyeYkG_Wfx3Ug/w400-h300/IMG_6559.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A surprising number of discs and spacers.....</span><br /></td></tr></tbody></table>Note that I also had a washer in addition to the 14 spacers. It's the dirty, blackened ring over on the right hand side in the photo above. The manuals and cutaway diagram make no mention of this washer.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">This series of discs and spacers are what compensate for changes in the viscosity of the hydraulic fluid. </span></span><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">Some
discs have the holes through the centre. For others, the holes are
offset. This is intentional as the zig-zag passage through the holes is
intended to 'frustrate the flow of hydraulic fluid.</span></span><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">The
holes in the discs are easily blocked and so all the parts benefit from
a good clean. The parts can be very gently shaken or tapped out. Don't
be tempted to use compressed air or anything sharp to force them out
from the gauze end, as you risk losing or damaging the discs (and
spacers).</span></span></div></div><br /><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">I gave all the parts a good wash and clean in petrol. All the holes in the discs looked clear - which is good becase I wanted to avoid the temptation to poke them through with wire or a needle. The discs and piston were also cleaned in my ultra sonic cleaner. The discs are sufficiently big enough to not get lost at the bottom of the clener and I was careful to keep stock of all the parts. I carefully rinsed and dried the parts and gave the internal parts a brush with LHM.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">Reassembly is straightforward but again complicated by both the photos and instructions given in the original printed copies of manual 518....... </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;">First back into the piston is the gauze, followed by a spacer. Next is a disc. </span></span><span style="font-family: arial; font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">I
noted in my unit that, when removed, the last disc removed - disc closest to the gauze - was
one that had it's hole offset. This is consistent with the cutaway
diagram earlier in this post. It's also consistent with French manaual 583. However (surprise surprise) the </span></span><span style="font-family: arial; font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">factory rebuild instructions in manual 518 contradict this and state that the first disc refitted </span></span><span style="font-family: arial; font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">should have a central hole...... Doubting manual 518 I put mine back together as I had found it.<br /></span></span><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><br />After the disc with offset hole, another spacer, then a disc with a central hole. I continued like this until all 14 disc and 14 spacers were refitted - making sure as each went in that it was lubticated with LHM and that it sat flat on the layer below. The last piece to go in was the washer/ spacer.</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> </span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">This is where manual 518 can be confusing. It's the terminology used. Throughout the procedure, the instructions refer to the two external hex screws as 'plugs'. The slotted adjuster (that should not be adjusted!) under the plug at end 'b' is referred-to as a 'screw', and the slotted cap on the end of the piston is referred-to as a 'plug'....For the assembly instructions, the 'plug' in the piston end is now called a 'screw'. It doesn't sound like a big change, but given the incorrect photo and lack of information about what is where, it's easy to get wrong-footed here. Anyway, I replaced the slotted plug/ screw on the end of the piston.....</span></span></div><div style="text-align: justify;"><span style="font-family: arial; font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwHKF-LQGKfSPB81tzAmVcoVs0lTJd6P_mSvuCVDKl63G6cgQYKpOJIOLxCTtU0EPhVku3bU_Bpxu_6JKWYWu-GfPg7fKKjBS9rz2nFEH1-1dTmO1GuvGZtaOClp3q5al96c4SmmVei7A6DJN16mSn-dF3ZHT3BmVex1Zic-0a0kjPmMWH98rV4w/s4032/IMG_6615.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwHKF-LQGKfSPB81tzAmVcoVs0lTJd6P_mSvuCVDKl63G6cgQYKpOJIOLxCTtU0EPhVku3bU_Bpxu_6JKWYWu-GfPg7fKKjBS9rz2nFEH1-1dTmO1GuvGZtaOClp3q5al96c4SmmVei7A6DJN16mSn-dF3ZHT3BmVex1Zic-0a0kjPmMWH98rV4w/w400-h300/IMG_6615.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Screw (or 'plug') in the piston</span><br /></td></tr></tbody></table></span></span><span style="font-size: small;"><span style="font-family: arial;">All good to go.......</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhW4A9UV_-l83zdsTlWs2vXHgXj-CTk3CLVtg2ggugb5hgXpKZva7vNKSGk5rvPKch9rnQSYNLqDuaws1Bo3YkEsJg8O--p7u1AialZs3y3XQQt1hyt1uyn3t3NARX6cwW9TC-1-5jehXN_glP7044pFNV_O_cc3XVnRP4F11OYpUpybWpIIQaIow/s4032/IMG_6614.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhW4A9UV_-l83zdsTlWs2vXHgXj-CTk3CLVtg2ggugb5hgXpKZva7vNKSGk5rvPKch9rnQSYNLqDuaws1Bo3YkEsJg8O--p7u1AialZs3y3XQQt1hyt1uyn3t3NARX6cwW9TC-1-5jehXN_glP7044pFNV_O_cc3XVnRP4F11OYpUpybWpIIQaIow/w400-h300/IMG_6614.JPG" width="400" /></a></div></span><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">The spring was lubricted and fitted inside the regulator. The assembled piston was lubricated and <u>fitted slotted-screw-end first</u>. In other words, it was fitted leaving the the gauze end visible.</span></span></div></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">A new 'O' ring seal was placed in the recess in the body end. These came with the kit for rebuilding the main 'gear brain'.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzGQiFJTgC2hko_RUWSGvMqtWB7OhdjPjQFqn_DQXunZtmObN63mur1oPup3E8ycOV4NtmUYgCOF4cX5DFY1FdE_xUadOhbUgJYzgTg8Zv0Kn4xx5EhKv3aQbGjtrQ5t3Yofui_lXuXhSYIKoBvW73XM3A9n7eiuUFsi4p5NtWT5zHi_16f4aDRQ/s4032/IMG_6616.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzGQiFJTgC2hko_RUWSGvMqtWB7OhdjPjQFqn_DQXunZtmObN63mur1oPup3E8ycOV4NtmUYgCOF4cX5DFY1FdE_xUadOhbUgJYzgTg8Zv0Kn4xx5EhKv3aQbGjtrQ5t3Yofui_lXuXhSYIKoBvW73XM3A9n7eiuUFsi4p5NtWT5zHi_16f4aDRQ/w400-h300/IMG_6616.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">New seal for the hex cap</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">The instructions say this should be fitted over the hex screw, but I put mine in the recess of the body as I felt I could be more confident that the plug then sat squarely and sealed when tightened. </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">Which brings me to.....</span></span><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">another word of caution here: t</span></span><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">he two hex screws have the same size threads and hex heads - but have diferent profiles to their inner faces. The screw at end 'b' is concave/ recessed inside. The screw for end 'a' is slotted. Manual 518 is again, not helpful here stating only to <i>"fit the plugs in the same positions as they occupied before dismantling"</i> - but not really reminding you which goes where. French manual 583 is more helpful. It omits this instruction and more clearly states that the parts should be refitted <i>"The cap (1) (recessed body in 'c') placed on the side of the relegation screw, in 'b' ".<br /></i></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">In a follow up instruction, manual 518 advises <i>"the plug (1) must enter by hand. If it does not, the spring is out of place"</i>. Now I also have a problem with this instruction.......referring to the cutaway diagram earlier in this post, 'plug 1' is at end 'b'. And it covers the adjuster screw that should <u>not</u> be adjusted. So why <u>wouldn't</u> plug 1 go back exactly as you removed it? Surely not for any reason to do with the spring?<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">I think the instruction in 518 (incidentally the instruction isn't in French language manual 583) must be referring to the hex plug (part 4) on end 'a': if the piston has been put in the wrong way round, or the end of the piston has not engaged with the spring, then maybe the piston sticks out a little too far and stops the hex plug (4) being fitted? I don't know for sure, and none of us should really need to be second-guessing Citroen.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">I put a new seal at the other end (end 'b') and replaced that hex screw. Surprise surprise, the plug <i>'entered by hand'</i>.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"> </span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">I fitted the gearchange speed regulator back on top of the 'gear brain'. Masking off holes and studs, it all got splashed with paint.</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihnmN0sX7vZJJbC1sy2-DtvnpEHnMani2YgdmqyWgtUXwX-Fa4TpRH7DnsCpZjpasKWIodxa4wrIwY-lZRCtru2Bf4ZH208zvAS2tC2Oit0BgaJy1cenyxYp24K4lKMPdMxrq7gObYil9JUleRE3YRIlwiOunYChHU4WmtC6qi4WFNcWa_x4_Q4Q/s4032/IMG_6619.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihnmN0sX7vZJJbC1sy2-DtvnpEHnMani2YgdmqyWgtUXwX-Fa4TpRH7DnsCpZjpasKWIodxa4wrIwY-lZRCtru2Bf4ZH208zvAS2tC2Oit0BgaJy1cenyxYp24K4lKMPdMxrq7gObYil9JUleRE3YRIlwiOunYChHU4WmtC6qi4WFNcWa_x4_Q4Q/w300-h400/IMG_6619.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">After masking and painting</span><br /></td></tr></tbody></table><br /><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">I painted the pair of pipes that fit be wtween the gear brain and speed regulator seperately. remebering to fit new sealing rings in the plate.....</span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8Pci5OuzCeBdbONl4I_yTT1LJkmhTfX6Y0uMkrws7DZgmp2sLwmUF06qbbYCNhTgoGd-TSi3J06mzfxH4htHbHXNVMij_0LZXwwn9AVkohYQDFBqgTQ2eyEVPiZz7ydJvLXYtiL69pf-mMEotM1fkF6iLd1Vdz_6jvEUbpmulwcDFxsr1YR68DA/s4032/IMG_6620.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8Pci5OuzCeBdbONl4I_yTT1LJkmhTfX6Y0uMkrws7DZgmp2sLwmUF06qbbYCNhTgoGd-TSi3J06mzfxH4htHbHXNVMij_0LZXwwn9AVkohYQDFBqgTQ2eyEVPiZz7ydJvLXYtiL69pf-mMEotM1fkF6iLd1Vdz_6jvEUbpmulwcDFxsr1YR68DA/w300-h400/IMG_6620.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">New O rings in the pipe sealing plate</span><br /></td></tr></tbody></table><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">........everything was reunited.<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeZc3gg6SF20WP_aVnivRUpM_5P2OTZ04k2xkP_f0Zyttmp7F91vK7dyVAPpuXOlKNV9PLfkhpWnbIPgnY2inqoSkG7JseoMV9BS9Lv-hmWrUIw8yUXZdkxw0qQQqgXn9MbjnQknJXdZg8gDj0pzLsGRrKxftuOcwworOhFQHnEtIbzIQ7n-0hAg/s4032/IMG_6631%201%20copy.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeZc3gg6SF20WP_aVnivRUpM_5P2OTZ04k2xkP_f0Zyttmp7F91vK7dyVAPpuXOlKNV9PLfkhpWnbIPgnY2inqoSkG7JseoMV9BS9Lv-hmWrUIw8yUXZdkxw0qQQqgXn9MbjnQknJXdZg8gDj0pzLsGRrKxftuOcwworOhFQHnEtIbzIQ7n-0hAg/w400-h300/IMG_6631%201%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">All done </span><br /></td></tr></tbody></table><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;">Don't be put off manual 518, it really is very helpful to have. Many of it's sections that aren't in manual 814 are finding their way into digital copies of 814. You can tell which they are because the operations tend to be numbered with a 'DX' prefix. But if what the instructions say, and what your eyes are seeing are different: dig a little deeper. Do some cross-checking. Seek out other advice. Don't take things at face value. Bon chance!<br /></span></span></div><div style="text-align: justify;"><span style="font-size: small;"><span style="-moz-text-size-adjust: auto; -webkit-text-stroke-width: 0px; background-color: white; caret-color: rgb(0, 0, 0); color: black; display: inline; float: none; font-family: arial; font-style: normal; font-variant-caps: normal; font-weight: normal; letter-spacing: normal; text-align: justify; text-decoration: none; text-indent: 0px; text-transform: none; white-space: normal; word-spacing: 0px;"><br /></span></span></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-39864973386350021902023-04-11T05:26:00.002+00:002023-05-24T20:33:07.256+00:00Hydraulic Gear Selector - Strip Down and Overhaul (Part 1)<div style="text-align: justify;"><span style="font-family: arial;">Having bought the rebuild kit several years ago, I have eventually got round to rebuilding the bvh 'hydraulic gear selector'.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd0-OJKnOVV8kbz82Rw9Y8hpmSTnH8STEw5mBiBzKKBnZbiv9GYrW---Lfx787vOfC5OkMix5RhGGav7eX2EeaPSBlK_dZGGz_IyphXIG6Udt1CjE6A0k8X1cAXfMXJ2ZS1owKjwtJWl8-bt-9kaNfU74-dMypX0ovZZa_Wq2Klg1smMVk0_ZqIw/s4032/IMG_6631%201%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd0-OJKnOVV8kbz82Rw9Y8hpmSTnH8STEw5mBiBzKKBnZbiv9GYrW---Lfx787vOfC5OkMix5RhGGav7eX2EeaPSBlK_dZGGz_IyphXIG6Udt1CjE6A0k8X1cAXfMXJ2ZS1owKjwtJWl8-bt-9kaNfU74-dMypX0ovZZa_Wq2Klg1smMVk0_ZqIw/w400-h300/IMG_6631%201%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">The 'hydraulic gear selector' of a hydraulic gearchange car</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">The first thing to say, is that I don't call this the 'hydraulic gear selector'. That's what Citroen and the manuals call it. I've always called it the 'gear brain'. It interprets the movement of the gear wand (yes - I call the gear lever the 'wand') and translates that into the selection of the relevant gear. So it's a brain - right? A hydraulic gear selecting brain. </span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-family: arial;">It's also worth noting that </span><span style="font-family: arial;">the
unit is actually two devices - the main 'gear brain' and also a
'gearchange speed regulator'. This second device was introduced to deal
with changes in fluid temperature and pressure that would otherwise
alter how the gear brain responded. And I don't call it a 'gearchange
speed regulator' either. I tend to call it a 'viscosity compensator' or
'viscosity regulator'. Take your pick....... In stripping and rebuilding the
'unit' I will deal with each of these devices seperately. Anyway, mine was (were) looking decidedly shabby. </span></div></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgW1Pe6mXzey44hmi1oDnuPLG_nk49McyW0mnRZtwUsUGVxhQO4Lh2NCn65AdH84HCgAJIR-iGscC5UCsfcXXzIBmJlWQvQg33WuzQtr03AcmxuiKqmcnvAL7EIwyVhInTNzczRSy_gVLmiJxiYW75XkEWvWcWlKux6GFNJjg__fxNgnSYLdJUBPQ/s3264/IMG_0135.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgW1Pe6mXzey44hmi1oDnuPLG_nk49McyW0mnRZtwUsUGVxhQO4Lh2NCn65AdH84HCgAJIR-iGscC5UCsfcXXzIBmJlWQvQg33WuzQtr03AcmxuiKqmcnvAL7EIwyVhInTNzczRSy_gVLmiJxiYW75XkEWvWcWlKux6GFNJjg__fxNgnSYLdJUBPQ/w400-h300/IMG_0135.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">'Hydraulic gear selector' and 'gearchange speed regulator'</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;">The paint had fallen off the aluminium body and the steel part had surface rust. I was keen to clean it out - partly because it seemed like a good idea and partly because I'd previously had clutch problems and so wanted to rule out the gear brain (told you) as a possible cause as well. </span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><div style="text-align: justify;"><b><span style="font-family: arial;">Workshop Manual Instructions - A Cautionary Note <br /></span></b></div><div style="text-align: justify;"><span style="font-family: arial;">English language instructions for stripping and rebuilding the gear brain can be found in manual 518 </span><span style="font-family: arial;">(which dates from 1966) and you will find the instructions there at step 25 onward of Operation DX.334-3. The instructions were not originally included in printed copies of English language manual 814, though you may find they are added into PDF copies from manual 518 - which dates from 1966. </span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">Where the 'gearchange speed regulator' is concerned, you need to be aware that </span><span style="font-family: arial;">while the instructions in French language manual 583 (volume 3) are correct</span><span style="font-family: arial;">, the instructions (and photos) in the English language manual 518 contain several errors! For a good few years these errors have been left as-is in digital versions of 518 (and 814 where added-in) but, at the time of writing (mid April 2023) have been corrected to mirror the French instructions. If you have a PDF copy of manual 518 or 814, then depending on when you downloaded it (and from where) the English instructions may (or may not!) have been digitally corrected. Unfortunately the one weakness of the digital versions is that here is no version control on the digital versions - so you don't know what may have been added or updated. If you want to keep a downloaded local copy of the manuals, you really need to download the 'current' copy every time to be sure. Which kind of defeats the object.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF2nw5EkbY0yRE5XRMXSI6_iVZMUN8OlWyOKwJDUxO34_b6nftdLlNNq01t-oeLyUONwqZ53pdj_CgYDc7fDsC0eIzUOF1sxeYYDNDZRm-39NggqItlAz57M5dIuRBMyDu6ppPP40EokIxPGmdJSNfm_liVS3WGdE4x2BRk1T59OmaDL9tJjMbmQ/s1042/manuals%20compared.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1042" data-original-width="921" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF2nw5EkbY0yRE5XRMXSI6_iVZMUN8OlWyOKwJDUxO34_b6nftdLlNNq01t-oeLyUONwqZ53pdj_CgYDc7fDsC0eIzUOF1sxeYYDNDZRm-39NggqItlAz57M5dIuRBMyDu6ppPP40EokIxPGmdJSNfm_liVS3WGdE4x2BRk1T59OmaDL9tJjMbmQ/w566-h640/manuals%20compared.jpeg" width="566" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Spot the difference: printed English copies of 518 have text and photo errors....</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">Last couple of point on the manuals: as the instructions are from manual 518 and 1966, they relate to cars with LHS fluid. The instructions tell you to clean and wash the parts in alcohol. For gear brains from LHM cars, the parts should be washed in petrol.</span></div></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">It's also worth noting that while the LHS gear brain instructions hold good for LHM carburetor cars, the gear brains of fuel injected cars are a little different. Mechanically I think the parts and construction are the same, but a noticable difference is how the 'viscosity compensator' is fitted to the top of the brain (more on that later). Anyway, overall there is enough common ground for the instructions to still be of use.</span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Initial Dismantling</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">I won't go into the details of removing the unit from a car. That is covered in the manuals. The only tip I will give is tthat's it's probably better to release the 'back' bolt of the double-bolt clamp connecting the gear selector lever to the slide valve of the brain (so that the clamp is left on the valve and gear brain - not the selector lever. The 'back' bolt is lined up better with the hole under the rubber bung and it just means that, when you come to connect it all back up, it's a little bit easier to tighten the bolt.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtGKd7Iv84_VJUUf4KEP349nMkRs1azcdqkfAIebELqHeuF4eCJoZ0Z7CVLvdw1_WACxQzd89xlVaKcfJlas-CsjeTKHE3hJ3bmXu7up6qyvjfqzhsZ8tjhmwCO4XSGOjODg_xlh5KPvd1jryDomPspiCHpoMOsZcXIF27uStxB1f46joQDns8fg/s3264/IMG_0172%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtGKd7Iv84_VJUUf4KEP349nMkRs1azcdqkfAIebELqHeuF4eCJoZ0Z7CVLvdw1_WACxQzd89xlVaKcfJlas-CsjeTKHE3hJ3bmXu7up6qyvjfqzhsZ8tjhmwCO4XSGOjODg_xlh5KPvd1jryDomPspiCHpoMOsZcXIF27uStxB1f46joQDns8fg/w300-h400/IMG_0172%20copy.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Double bolt clamp on the selector linkage</span><br /></td></tr></tbody></table> When it comes to dismantling, the manual suggests you build a stand to hold the gear brain (stand 'MR. 3053-200').</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihcrg9q6rixcFcYtS321pLFNAu-Y5s9eldEwp2p5wnVygDgnf4OZyVUVKMKG7T6I0uACxo6y3rB8nUaLvQ9VuSXM2ob9lkFPxhv8mN3X6s00I8S8r5ZJaOkXDlBVhp2IN52K--cllfnx7SdVOIxCtT8Zo34iXcSWi5noWe2eZJa2oKgo8_mZP0sw/s666/stand.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="666" data-original-width="446" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihcrg9q6rixcFcYtS321pLFNAu-Y5s9eldEwp2p5wnVygDgnf4OZyVUVKMKG7T6I0uACxo6y3rB8nUaLvQ9VuSXM2ob9lkFPxhv8mN3X6s00I8S8r5ZJaOkXDlBVhp2IN52K--cllfnx7SdVOIxCtT8Zo34iXcSWi5noWe2eZJa2oKgo8_mZP0sw/w268-h400/stand.jpeg" width="268" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Another Citroen 'Special Tool'.....</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">I just rigged something up with a piece of old angle. I just needed to drill a few extra holes for the bolts and to make room for the shaft that sticks out.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6z8zjzwF8_2p4a9wqdiIcDQKGrXnnsEvVsRfrdzxaeQ2EO5DuJCkApvxjOzqQs4UudrjJ6QzTnWoU6K7ZQfluZOzUAPstHJpTRTGtldJG2xZrxAt3GtIboehQrbyCMy6nKtn8qbvr5EjvEWmCReWnHBHjY6iZdYw79UfAJrE1dIVdNx94yrMgqA/s4032/IMG_6503.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6z8zjzwF8_2p4a9wqdiIcDQKGrXnnsEvVsRfrdzxaeQ2EO5DuJCkApvxjOzqQs4UudrjJ6QzTnWoU6K7ZQfluZOzUAPstHJpTRTGtldJG2xZrxAt3GtIboehQrbyCMy6nKtn8qbvr5EjvEWmCReWnHBHjY6iZdYw79UfAJrE1dIVdNx94yrMgqA/w400-h300/IMG_6503.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Home Made Stand</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;">With the gearbrain mounted on it's end I first removed the gearchange speed regulator and the associated 'S' shaped pipes that join it to the gear brain.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZRPIhXSDPthvdzSv5O2HGBkp-jTLw0X1PBahmTMVGT4tMaokF7sLervZ71h3QHlCMBp_bC6mi_fkS3fpsH_0kRjYxpt-KCueiSYsE8ljQA4yxnYuv9RDKvaI_dUOJaRq94HbyMjgkBtTWVqjJJ0NyUCLPHZSDqQQm7oCFJP9YPn1TtjOb8hWWhg/s4032/IMG_6509.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZRPIhXSDPthvdzSv5O2HGBkp-jTLw0X1PBahmTMVGT4tMaokF7sLervZ71h3QHlCMBp_bC6mi_fkS3fpsH_0kRjYxpt-KCueiSYsE8ljQA4yxnYuv9RDKvaI_dUOJaRq94HbyMjgkBtTWVqjJJ0NyUCLPHZSDqQQm7oCFJP9YPn1TtjOb8hWWhg/w400-h300/IMG_6509.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Gearchange Speed Regulator Removed.....</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;">With the viscosity compensator out of the way, the front end cover of the 'brain' can be removed. The 'front' being the end that points towards the nose of the car.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">This cover holds a powerful spring for the syncro delay return pistons and the manual says each of the nuts and bolts of the cover should be released very gradually in turn - just one flat (of their hex heads) at a time. This is to ensure that the cover lifts off straight and doesn't snag.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4BMQ0Zbu8NsHtJ3xDcL1RnD0NP8ze0KtMTV_1QkxvvVlitl6EJUt9oOCXYMXKJ1QY_-XPyF4VwEvUJFpcpDqOB2AmBcfWliGKsMaQuzvqOZLDuVI7iZ0F9cn5Pz2GjWvRE-xk9TiPUsD8isdaFsn5GJ_ft--O2LNJQ4xK0o3w3U_rYDBDRo-K8Q/s4032/IMG_6514.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4BMQ0Zbu8NsHtJ3xDcL1RnD0NP8ze0KtMTV_1QkxvvVlitl6EJUt9oOCXYMXKJ1QY_-XPyF4VwEvUJFpcpDqOB2AmBcfWliGKsMaQuzvqOZLDuVI7iZ0F9cn5Pz2GjWvRE-xk9TiPUsD8isdaFsn5GJ_ft--O2LNJQ4xK0o3w3U_rYDBDRo-K8Q/w400-h300/IMG_6514.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Front End Cover</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"> I will confess that I didn't follow the 'one flat' rule studiously, but it soon became clear how easy it was for the case to jam on the studs and I did take my time on this stage. It was also clear how the stand helps to keep the unit steady and frees up one of yout hands - worth making one.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIHw4iq10S4fDsJ3BmeaUOh3rOBiXTywuov7Q4NyEHwSoggkshaGCmtDd1Wq4BdxsLHssp3meL5cbwxmgsGs3neVEhaq9RTuJ-JVlh9deqWjyavf9AupdwcbMAkVEj745siz4pbm-Zf9VOs0RNxpnLzOVprsCzUDPkOoN_OWC4fyEZM8x35AM6Tw/s4032/IMG_6519.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIHw4iq10S4fDsJ3BmeaUOh3rOBiXTywuov7Q4NyEHwSoggkshaGCmtDd1Wq4BdxsLHssp3meL5cbwxmgsGs3neVEhaq9RTuJ-JVlh9deqWjyavf9AupdwcbMAkVEj745siz4pbm-Zf9VOs0RNxpnLzOVprsCzUDPkOoN_OWC4fyEZM8x35AM6Tw/w400-h300/IMG_6519.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">The front cover - released</span></span></td></tr></tbody></table>With the nuts and bots removed, the innards (and the spring) were revealed. Also revealed was thick black goo and I was glad I'd tackled this job (remind me I said that later).</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAHfqQcKSZjna1niwg9WFEHzG9ECmX3LCaVGPonqE1OTENY-nuqUhMKE9bI_5bQRlyNrUaDMDBYI-0sG0e8A7VJ90h5cNYsGAwPkQjVLmMJfr0xp3IELNwMfCgHzowb8vqG2DX7gYqRbHONBL57y7E0efXq08MGe0pGHHlE_qhTptcLt8jZBBJ6A/s4032/IMG_6520.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAHfqQcKSZjna1niwg9WFEHzG9ECmX3LCaVGPonqE1OTENY-nuqUhMKE9bI_5bQRlyNrUaDMDBYI-0sG0e8A7VJ90h5cNYsGAwPkQjVLmMJfr0xp3IELNwMfCgHzowb8vqG2DX7gYqRbHONBL57y7E0efXq08MGe0pGHHlE_qhTptcLt8jZBBJ6A/w400-h300/IMG_6520.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">That is a BIG spring.....</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNq3Fd_dKucIg-SYVS6VMKXsNuKFv3mODjk5Pv1GUwkqUjUcU4WsHAlT5F7Y5htsmogszHppbEo70MPutPpEaslBceZKI8YqvDBt7Vr0YIOhpTj8c_aeVNb2vXo7UcDFBfNOMm3JuwKTWSQgWyDvcj-yce3Pw0UI901qZQecsw7YI4afRrRCpJXQ/s4032/IMG_6523.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNq3Fd_dKucIg-SYVS6VMKXsNuKFv3mODjk5Pv1GUwkqUjUcU4WsHAlT5F7Y5htsmogszHppbEo70MPutPpEaslBceZKI8YqvDBt7Vr0YIOhpTj8c_aeVNb2vXo7UcDFBfNOMm3JuwKTWSQgWyDvcj-yce3Pw0UI901qZQecsw7YI4afRrRCpJXQ/w400-h300/IMG_6523.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">.....and a dirty spring</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;">Turns out the syncro return spring is actually two springs - one inside the other.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikclly606s2sieheKQDfPdS2sQ9KKPpKBf2FmKxLhpn5HfPhvlxO0OJgYmVoEAjlrMymoy089py87TTDa1PTC1PV8s-lSlmy1K96G3Q_J6uE7s8vCikiYmPYyzEIEdcShLfJYCwrewVJwgNa6Ze4QBOKyXNnKZVhRCdUwsqsxmoqkIYE0vDYvRMA/s4032/IMG_6526.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikclly606s2sieheKQDfPdS2sQ9KKPpKBf2FmKxLhpn5HfPhvlxO0OJgYmVoEAjlrMymoy089py87TTDa1PTC1PV8s-lSlmy1K96G3Q_J6uE7s8vCikiYmPYyzEIEdcShLfJYCwrewVJwgNa6Ze4QBOKyXNnKZVhRCdUwsqsxmoqkIYE0vDYvRMA/w400-h300/IMG_6526.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Second spring inside the outer spring</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-family: arial;">There are thrust plates on the ends. These are different shapes and it's important to note which goes where.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrV4o7GZJm51OvRcL4tDUH9HpXrcizhdUjFFJp_npXg-R4HO02YTfiF2cSE1FkuItuqU5XxFzWQOUyNjYZZlBhCtfPqmKBpi2uos5TLF_kkwdVmC7OIBV2C1SHddbxRxoBA21vqZ7WBelwNl1rSGLNVPFKxIAyZ74V5i0ouqe9lNwZ2_9sDHK2sw/s4032/IMG_6529.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrV4o7GZJm51OvRcL4tDUH9HpXrcizhdUjFFJp_npXg-R4HO02YTfiF2cSE1FkuItuqU5XxFzWQOUyNjYZZlBhCtfPqmKBpi2uos5TLF_kkwdVmC7OIBV2C1SHddbxRxoBA21vqZ7WBelwNl1rSGLNVPFKxIAyZ74V5i0ouqe9lNwZ2_9sDHK2sw/w400-h300/IMG_6529.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Syncro delay return springs</span><br /></td></tr></tbody></table>With the syncro delay return springs out of the way, the large main gear selector slide valve can be removed. </span><span style="font-family: arial;">You shouldn't need telling but be very careful not to drop or scratch this. Same goes for the shaft from which it was removed.</span></div><div style="text-align: justify;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrNm3GtaoXxyKVvHQcBzU6lHhZSxlGet3Ie_MKo9vWp4HkSYk1XEaTEwk2VsTNTGrKT1Va4dUABP2wlEKRjpOIJM45B24Oe-JlYrnFeFoVD5XMxnG6TYOQTLri412DCQA34nTvlQIu05OrgcSwQPnVGwrVsVbmRubYyMMt0wO9NxGcmRiiPonWAQ/s4032/IMG_6533.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrNm3GtaoXxyKVvHQcBzU6lHhZSxlGet3Ie_MKo9vWp4HkSYk1XEaTEwk2VsTNTGrKT1Va4dUABP2wlEKRjpOIJM45B24Oe-JlYrnFeFoVD5XMxnG6TYOQTLri412DCQA34nTvlQIu05OrgcSwQPnVGwrVsVbmRubYyMMt0wO9NxGcmRiiPonWAQ/w400-h300/IMG_6533.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The gear selector slide valve</span><br /></td></tr></tbody></table></span><span style="font-family: arial;"> And with the base of the springs cleaned up you will see this....</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNcQVCCNtV7FYgYyNbSd6z0oq9DENFPiHuZNzhMkb78EEMFU41arsX4dS-uVHwjLY4rSy9S1kn0YQ6_NkscKcIqraPAl_bwKf-GBJpMYwxggaCvfjVP8OP2lk_SIV99wc9sTrVsw4fzXd-ykmrvb0yaK9k91Y-luN3-u4znc1dkWJnHOEKS_o3jg/s4032/IMG_6531.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNcQVCCNtV7FYgYyNbSd6z0oq9DENFPiHuZNzhMkb78EEMFU41arsX4dS-uVHwjLY4rSy9S1kn0YQ6_NkscKcIqraPAl_bwKf-GBJpMYwxggaCvfjVP8OP2lk_SIV99wc9sTrVsw4fzXd-ykmrvb0yaK9k91Y-luN3-u4znc1dkWJnHOEKS_o3jg/w400-h300/IMG_6531.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Head of a syncro delay piston</span><br /></td></tr></tbody></table><span style="font-family: arial;">It's the nipple end of one of the syncro delay pistons. On the end of the gear brain clamped to the stand, you will see the end of the 'auxilary clutch control slide valve' (or 'the auxilary clutch control slide valve' as I like to call it) sticking out. It has the hole through the end - for the hook of the auxilary clutch mechanism. This is it.<br /></span></div></div><div style="text-align: justify;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLbFn4u12QguSMsY0shxs3we84rV5FeCF5WjdHuKSfKHZE0aF1R7MvWqtJxBuPWhdnUo7VET4yZgxWUslRBgHrgVIAjgxqvtY-HbxLdWVRqSfEMOA7MX0BwpHM9RmoVZs0-OLfUuGeDrWDBTdxxVvvYbYyHwW9fuSJLwZba7ozPllwGeo7q3WH_Q/s4032/IMG_6640.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLbFn4u12QguSMsY0shxs3we84rV5FeCF5WjdHuKSfKHZE0aF1R7MvWqtJxBuPWhdnUo7VET4yZgxWUslRBgHrgVIAjgxqvtY-HbxLdWVRqSfEMOA7MX0BwpHM9RmoVZs0-OLfUuGeDrWDBTdxxVvvYbYyHwW9fuSJLwZba7ozPllwGeo7q3WH_Q/w400-h300/IMG_6640.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Tip of the 'auxilary clutch control slide valve'</span><br /></td></tr></tbody></table>Push this into the unit <u>slowly and carefully</u> and (with the end cover and springs now out of the way), you will see the first syncro delay piston stsrt to emerge from the top end. Again - be careful not to push this out and drop and damage it. Grab it as soon as you can and put it aside safely. Other syncro pistons will be removed and you need to make sure you do not muddle these up. they need to go back in in reverse order of removal. Citroen recommend that you make a little stand. </span><span style="font-family: arial;">I didn't do woodwork at school, so just carefully laid things aside.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB23-CipeBYH_epaEkTF4smI7Dl7u7zC2zUyJ4vFOfw_qp7GsOHfvAt-bWB0BJ39I-sBdv_McH1C-dfx3XZWYCc9COQ-klp161ytIolJsE_iwnR8ADFFFQUEQQHAuYs505JX44s71ZUd5GuCUyqQ3W0ip6-cDTHe946k_zLkXFj7zi0-x9cvybgg/s731/rack.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="481" data-original-width="731" height="264" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB23-CipeBYH_epaEkTF4smI7Dl7u7zC2zUyJ4vFOfw_qp7GsOHfvAt-bWB0BJ39I-sBdv_McH1C-dfx3XZWYCc9COQ-klp161ytIolJsE_iwnR8ADFFFQUEQQHAuYs505JX44s71ZUd5GuCUyqQ3W0ip6-cDTHe946k_zLkXFj7zi0-x9cvybgg/w400-h264/rack.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Rack to store the pistons and other parts</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;">With the first piston removed, you will find an 'O' ring seal in the circumference of the chamber. You need to CAREFULLY winkle this out. This is made all the more difficult by the seals being hardened over time. The technique I used was to skewer the seal with a dental pick and then pull it's edge in sufficiently to get something behind it. </span><span style="font-family: arial;">You need to be EXTREMELY careful that you do not scratch the surface of the chamber as this can ruin the gear brain. </span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">In this diagram, parts 12 and 13 are the syncro delay pistons and part 14 is the auxilary clutch control slide valve. The 'O' rings aren't numbered but are around parts 12 and 13.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrlXJPNey2bPrUtntCNhtjXqTAyGUGmenHnSzsrwdbBd4BkgR4jREPQVzNNWtQIZaYmdyxbN9Y9LlmK1_1K22hIPJZ7ctroq6MhVcUIhSZ6n2n2A9-S06EM20abjy4v8UjyMyLHexgU7tE37C5QLL2DlFoc9gI-s-BJzV28N01pVtqkzM-571zjA/s769/cutaway.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="769" data-original-width="522" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrlXJPNey2bPrUtntCNhtjXqTAyGUGmenHnSzsrwdbBd4BkgR4jREPQVzNNWtQIZaYmdyxbN9Y9LlmK1_1K22hIPJZ7ctroq6MhVcUIhSZ6n2n2A9-S06EM20abjy4v8UjyMyLHexgU7tE37C5QLL2DlFoc9gI-s-BJzV28N01pVtqkzM-571zjA/w434-h640/cutaway.jpeg" width="434" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Diagram showing the syncro pistons in situ</span><br /></td></tr></tbody></table>Right, with one syncro delay piston and seal removed, you need to do it all over again..... carefully push the end of the auxiliary clutch control slide valve a little further and another piston will emerge at the top end. (Remember not to muddle this piston with the previous piston). Now you need to remove the 'O' ring seal for the second piston. This is deeper in the chamber and less easy to get at. You need to take even more care with winkling it out. Things only get harder. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhghbHjk7rjMHXGiruXVe_DLyJuu4wXhVpUP90QC8TUpicKqQv1OxefTHW2SfBnU2aNHRCFVbvqw0uAhUQIzq8JFn1oDPEpq4coXwYPOUBLaiu1ukyZrxCODfRuOzqjMPipwyhAsQY-lIZ5GocjGO7P2fKUOkoMQS6ZzqSvZ9Sp_kdx1FJyik_l3w/s4032/IMG_6589.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhghbHjk7rjMHXGiruXVe_DLyJuu4wXhVpUP90QC8TUpicKqQv1OxefTHW2SfBnU2aNHRCFVbvqw0uAhUQIzq8JFn1oDPEpq4coXwYPOUBLaiu1ukyZrxCODfRuOzqjMPipwyhAsQY-lIZ5GocjGO7P2fKUOkoMQS6ZzqSvZ9Sp_kdx1FJyik_l3w/w400-h300/IMG_6589.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">It's increasingly hard to access and remove the old '' rings.</span><br /></td></tr></tbody></table>To
remove the two remaing syncro pistons (yes - there are still two to
go), you need to use a drift or similar to push the auxilary clutch
control piston further up into the chamber. Once again, whatever you
use, make sure you don't scratch the edges of the chamber. Removing
the deep 'O' rings for the last two pistons <u>is quite tricky and brings
the most risk</u> of scratching the walls of the chamber. Be warned!</span><span style="font-family: arial;"> Finally, with the last piston and 'O' ring out, the auxilary clutch control slide valve can be removed.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I put the parts aside in seperate bags - marked so that I could make sure I put them back in the right order after cleaning and inspection.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8qD_Kders-GHyINPPX0x-ZI2HIYIKfmipDwvv1CPEo8XqRkIMKlTn55VHB7VC5V1Rrr3WfRertRG1c1r9tbA2Or2IxGRjcIDbDn9T6VnSZopXIfq1ywNCVZ9f2_ddsUyigHS45WAvJPuPaJZvbf98xsGzSdoswnSH4611FDNGANDMOLaV0ImEEA/s4032/IMG_6591.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8qD_Kders-GHyINPPX0x-ZI2HIYIKfmipDwvv1CPEo8XqRkIMKlTn55VHB7VC5V1Rrr3WfRertRG1c1r9tbA2Or2IxGRjcIDbDn9T6VnSZopXIfq1ywNCVZ9f2_ddsUyigHS45WAvJPuPaJZvbf98xsGzSdoswnSH4611FDNGANDMOLaV0ImEEA/w400-h300/IMG_6591.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Bagged and tagged......</span></td></tr></tbody></table></span><div style="text-align: justify;"><span style="font-family: arial;">With</span><span style="font-family: arial;"> the stand having served it's purpose for now, I removed the gear brain and tackled the back end cover on the bench.This revealed another spring (not as big) and more goo (but not as much).</span></div></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieW5DVGPVu8DdH3UR9zjd0s_BAxM9RHaVjauHUtQdieEVLSPkCIeH2hJCUw8Pt7TGSWYAWAsDTUi_O7EVZvBysL-FxDJZ8BFFD1jFPIOcJOJVKQQ9yRBKSuKkuykw3HPZ1ddjvqT9emkDeg4HGbh0B1VvEJeXt2-KDhpOV7IH4iPRhuJbQCQiGcw/s4032/IMG_6535.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieW5DVGPVu8DdH3UR9zjd0s_BAxM9RHaVjauHUtQdieEVLSPkCIeH2hJCUw8Pt7TGSWYAWAsDTUi_O7EVZvBysL-FxDJZ8BFFD1jFPIOcJOJVKQQ9yRBKSuKkuykw3HPZ1ddjvqT9emkDeg4HGbh0B1VvEJeXt2-KDhpOV7IH4iPRhuJbQCQiGcw/w400-h300/IMG_6535.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Rear end cover removal</span><br /></td></tr></tbody></table><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEgouYUQxgJ1EEXNoXEoW8HIgbSHIvYCO8STp83ea0E885SwKvPi0YFlua3y79JL7OKir94EDZGmGfxJ7KWu0tpgQfLdCKF1mpRA9lbgGFn74Lzscm43LeNxWb5cEOmOya4po-9an13_879zewinyx7czizbILfboUisQg5aTSpLFoiTfJw3rg1w/s4032/IMG_6537.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEgouYUQxgJ1EEXNoXEoW8HIgbSHIvYCO8STp83ea0E885SwKvPi0YFlua3y79JL7OKir94EDZGmGfxJ7KWu0tpgQfLdCKF1mpRA9lbgGFn74Lzscm43LeNxWb5cEOmOya4po-9an13_879zewinyx7czizbILfboUisQg5aTSpLFoiTfJw3rg1w/w400-h300/IMG_6537.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Rear end cover removed</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">It's worth noting at this point - and before atention turns back to the main body - that there is a 'secret' seal tucked away in the cover. I took a photo to remind me....<br /></span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL80cpZHR2iw4sfpmvnWU7uINyB6EwmGiAsPaQz5ycHjZM6C49Ax4ljZar2O3h9-8hDgzvU4DeQh3mwu15VCeQtaTrQyn-Hatx8bRF8M3H8QOc5zHNhWegk5JkRlD0J7lKC5eZIzjR2ZulgowuQcr6iwouJvXCwtzOTEODHMtT6Ttp8VRoemyQ2w/s4032/IMG_6543.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL80cpZHR2iw4sfpmvnWU7uINyB6EwmGiAsPaQz5ycHjZM6C49Ax4ljZar2O3h9-8hDgzvU4DeQh3mwu15VCeQtaTrQyn-Hatx8bRF8M3H8QOc5zHNhWegk5JkRlD0J7lKC5eZIzjR2ZulgowuQcr6iwouJvXCwtzOTEODHMtT6Ttp8VRoemyQ2w/w400-h300/IMG_6543.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">A note to myself....</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">Beneath the spring is a disc - a thrust washer - Under the thrust washer is the very tip of the automatic gearchange slide valve. (It's part 4 in the diagram earlier in this post).</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLLy20bloifRgrq89a5A7v_3yY5fXdzlpPvLCJP34e8Cii2kMqx0bX0BrWJ9tj7r9d2NyjhWIHj-C-0E1V2Dq9WQ-V_iCvDcvlP7vacpKWswodbWA70h25p4X44aMW4UfNgoUHDvds_Ed4FxbrH4F8_4BW09yd2gnd4fTSdvnQBgaWgW3GHEUr8g/s4032/IMG_6538.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLLy20bloifRgrq89a5A7v_3yY5fXdzlpPvLCJP34e8Cii2kMqx0bX0BrWJ9tj7r9d2NyjhWIHj-C-0E1V2Dq9WQ-V_iCvDcvlP7vacpKWswodbWA70h25p4X44aMW4UfNgoUHDvds_Ed4FxbrH4F8_4BW09yd2gnd4fTSdvnQBgaWgW3GHEUr8g/w400-h300/IMG_6538.JPG" width="400" /></a></div><span style="font-family: arial;">Pushing the end of this valve SLOWLY into the shaft from the back end first pushes out a small plug from the other end (part 3 in the diagram). </span><span style="font-family: arial;">Don't lose this! Continue pushing SLOWLY and, one by one five small pistons will pop out in turn. NOTE: the slide valve will not, and should not,go all the way through the shaft<br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDbVyRwV4sHn5P0IZAtOOnT1HeLP8vfwII1bgBYD5uI8BiwTLMt5W2tFYz1eOraiIGG9K2COT-lkhlQLwG1N4A32vImqcuOMDR0tvMRXPv5JarLyz-K5_G7xLpo_xsjhx3B-DeoI7kdnFjs45wFtLtwwbsW2gM5leVKqjt2aLyd1D6ncgfi2zKRw/s4032/IMG_6539.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDbVyRwV4sHn5P0IZAtOOnT1HeLP8vfwII1bgBYD5uI8BiwTLMt5W2tFYz1eOraiIGG9K2COT-lkhlQLwG1N4A32vImqcuOMDR0tvMRXPv5JarLyz-K5_G7xLpo_xsjhx3B-DeoI7kdnFjs45wFtLtwwbsW2gM5leVKqjt2aLyd1D6ncgfi2zKRw/w400-h300/IMG_6539.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">One of the small gearchange pistons starting to emerge</span><br /></td></tr></tbody></table>There are no 'O' rings to worry about this time but, again, Citroen say the pistons need to be replaced in the order in which they were removed - so don't muddle them up. Store them safely and carfully as, when the time comes, they will need to be reftted in reverse order. Finally, with the pistons out, the slide valve itself can be pushed/ pulled out.</span></div><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIEo_OTm1nsBEvGImUVK22wd3Ft7tZqarrkUqmrKUU81-NvM2iaRgGjcWb_6gzzYT5BFA54KmTmZM9kklw3DQn__1ZPKp83_lM5j1v1vYdTQbdqOuJawfeW_ed8kogrY0hYdYAWpo6H1dpMsfZoAnMQvN9HY34M7aLYLboJv_QXY8qtfen8sJtYg/s4032/IMG_6541.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIEo_OTm1nsBEvGImUVK22wd3Ft7tZqarrkUqmrKUU81-NvM2iaRgGjcWb_6gzzYT5BFA54KmTmZM9kklw3DQn__1ZPKp83_lM5j1v1vYdTQbdqOuJawfeW_ed8kogrY0hYdYAWpo6H1dpMsfZoAnMQvN9HY34M7aLYLboJv_QXY8qtfen8sJtYg/w400-h300/IMG_6541.JPG" width="400" /></a></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFmuVMimDm59ysh4SE-N4PcTRxSf1oDXJ4rQ2GZ4H9hWdH69C9CCySBAI5fBpOjraxk1GxjeY-S0i5C5xXy0dYoS7CFyK7ZTiEH6N9fu7F_jOoxLLOtaNK971f_Pl1uxoKA9scr0cP8oAR1rc4839g3Ri76IvwC1QGGXqZvClyq0higgHhVbt3MQ/s4032/IMG_6542.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFmuVMimDm59ysh4SE-N4PcTRxSf1oDXJ4rQ2GZ4H9hWdH69C9CCySBAI5fBpOjraxk1GxjeY-S0i5C5xXy0dYoS7CFyK7ZTiEH6N9fu7F_jOoxLLOtaNK971f_Pl1uxoKA9scr0cP8oAR1rc4839g3Ri76IvwC1QGGXqZvClyq0higgHhVbt3MQ/w400-h300/IMG_6542.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Removing the slide valve</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">Other than very carefully cleaning and preparing everything, that's 'disassembly'.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiS_V9f6ebxNJ1W4kuCVGE1jw-vI02dnX92jTuvZarH5O87jlhw36aYpOJzg2W-3VbhMP_6p3wwDLch5luzSUh6J_Xg7Fy3dg6eucxvDJu0xvm4d3CXZtVwNZ-NlBG71ws_mqxRtc_6m2SIKMM1k6_8F3zDBdxby-usSyLCoy7_vEQFIFu7Jb5gcg/s4032/IMG_6565.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiS_V9f6ebxNJ1W4kuCVGE1jw-vI02dnX92jTuvZarH5O87jlhw36aYpOJzg2W-3VbhMP_6p3wwDLch5luzSUh6J_Xg7Fy3dg6eucxvDJu0xvm4d3CXZtVwNZ-NlBG71ws_mqxRtc_6m2SIKMM1k6_8F3zDBdxby-usSyLCoy7_vEQFIFu7Jb5gcg/w400-h300/IMG_6565.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Gear brain parts</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">Rebuild
kits are readily available. Some contain new springs, others do not. They all seem to contain a large number of
small 'O' ring seals, but it turns out that these are just plate seals
for the several hydrualic connections to and from the outside of the
hydraulic gear selector. I mean 'gear brain'. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQ3wMffMhyqkzCEP1jGivQgcsEpcnbd3PhXikSoPD40N_GPz9ZQVUq1oj1D4-SxqxH01lhl4Lf3WDTH2WUtoYpYe-D2he1tcXfmQctIUYMCsa1-Qi8eFZ7WxcuEntTnH74CeXO5Ktj3CWwdLwatiYikFZKoR1YstRkAeeQXUM89EzFh0LGujf0yQ/s1382/kit.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="699" data-original-width="1382" height="325" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQ3wMffMhyqkzCEP1jGivQgcsEpcnbd3PhXikSoPD40N_GPz9ZQVUq1oj1D4-SxqxH01lhl4Lf3WDTH2WUtoYpYe-D2he1tcXfmQctIUYMCsa1-Qi8eFZ7WxcuEntTnH74CeXO5Ktj3CWwdLwatiYikFZKoR1YstRkAeeQXUM89EzFh0LGujf0yQ/w640-h325/kit.jpeg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">There are a number of different rebuild kits available</span><br /></td></tr></tbody></table>Surprisingly, considering
the complex job the gear brain does, it only contains five 'O' ring
seals. But don't forget that the slide valves are manufactured to a fine
tolerance interference fit. Plus you need a couple of replacement paper
gaskets of course. My kit was simpler and cheaper and did not include springs.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">Assembly is (of course) the reverse of disaasembly.....First the gearchange control slide valve was lubricated with LHM and carefully dropped into it's shaft.</span></div><div style="text-align: justify;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxr7fRLOFqTkeihjopKK3fmMyOOXdwGQLDl3vpan6oS-WbwpW8HuhCH0YgtAz7mmHqWBU6_zEDRkQdxy1BywLXHo09suX7mewM9z6KktRmGb9zhqcQDPLgbFbqywPHufRBk7Kk3-uH9y1fkacNcp1MU9bEuyNPjRy_XIeG6VhEO568M_0DT0I32A/s4032/IMG_6574.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxr7fRLOFqTkeihjopKK3fmMyOOXdwGQLDl3vpan6oS-WbwpW8HuhCH0YgtAz7mmHqWBU6_zEDRkQdxy1BywLXHo09suX7mewM9z6KktRmGb9zhqcQDPLgbFbqywPHufRBk7Kk3-uH9y1fkacNcp1MU9bEuyNPjRy_XIeG6VhEO568M_0DT0I32A/w400-h300/IMG_6574.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Gearchange control slide valve</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;">It should be a good tight fit but should not need any forcing.The thrust washer and spring can then be perched on top and a new gasket - brushed with LHM - was fitted. </span></div><div style="text-align: justify;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1J4785heJOmixudo1-LnkgZGBfpXDPtRLj36Y9k3TwlpLohGt1-zocaMDczPWBffGPkBViyDHTIBRrBCD6O4Gj5rmDWLFC82tN12xK2unoBFo-flw-yfkcNaRN8dLnG_xHT4mZDWTZ3iVreUthKywZS1rPnzg7eqZi0RJCVyepSEekqXPXfG5OA/s4032/IMG_6578.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1J4785heJOmixudo1-LnkgZGBfpXDPtRLj36Y9k3TwlpLohGt1-zocaMDczPWBffGPkBViyDHTIBRrBCD6O4Gj5rmDWLFC82tN12xK2unoBFo-flw-yfkcNaRN8dLnG_xHT4mZDWTZ3iVreUthKywZS1rPnzg7eqZi0RJCVyepSEekqXPXfG5OA/w400-h300/IMG_6578.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A new gasket was fitted</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"> And, of course, a new seal was put in the appropriate recess in the back cover (remember?).</span></div><div style="text-align: justify;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnn8lDZ4KKDbxZYM6fD-n79dt4c4NItbZ6TuFJHnOboCNdCa3PU0EzR1G8nvgmNVdQ9gy-mhKAMz-XD0MHyQAPLRRCA1iheEg2j2bqqxF2j7syflyvyDSb7vqS7fkRD0im08OpNOAdFlJcBQg1_tGk_DM09LDoBRZcDRbVVaUSRFD1VhJHXqzjpQ/s4032/IMG_6579.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnn8lDZ4KKDbxZYM6fD-n79dt4c4NItbZ6TuFJHnOboCNdCa3PU0EzR1G8nvgmNVdQ9gy-mhKAMz-XD0MHyQAPLRRCA1iheEg2j2bqqxF2j7syflyvyDSb7vqS7fkRD0im08OpNOAdFlJcBQg1_tGk_DM09LDoBRZcDRbVVaUSRFD1VhJHXqzjpQ/w400-h300/IMG_6579.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A new 'O' ring for the back end cover<br /></span></td></tr></tbody></table>The new 'O' ring seal meant that the cover had to be lightly pressed (by hand) into place. The bolts and fixings were then tightened.</span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">I put the unit back on my homemade stand.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIoALmqEAcLmZ9S6n7Ta_iMgsSkjFvcs44q7RbRsePX4fr_RkgpfEqlclS0LX_X6JUCIDzBjBTYOepkW9OS3MTUr6Gf_KLcLtNnk5g4NV8FPlGMRv3cERnCQ5OQqdX6WGdVvAhl3dHyBB5p3YsUcGIuOTEudjsuYMemy-Co0WV79jJWtgYgzxZzg/s4032/IMG_6583.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIoALmqEAcLmZ9S6n7Ta_iMgsSkjFvcs44q7RbRsePX4fr_RkgpfEqlclS0LX_X6JUCIDzBjBTYOepkW9OS3MTUr6Gf_KLcLtNnk5g4NV8FPlGMRv3cERnCQ5OQqdX6WGdVvAhl3dHyBB5p3YsUcGIuOTEudjsuYMemy-Co0WV79jJWtgYgzxZzg/w400-h300/IMG_6583.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Back on the stand</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;">From the front end of the body, the five gearchange shaft was lubricated..... </span></div><div style="text-align: justify;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3wvYuFnn-Cb4diEbNGWrvVHxbwrMtC-iAbsWD-IGnVp-4xESQtGwBqBx_Q1SgT6w8GqboiPlkb6sEp_4W9b4Di0NzSvFWyRxLXIf4fqaUhplVrvuRIlvVGsdrbVyYy_x9urs7Gx5fvR7Mcc62BuXrX1FtGJohoRyZmYe6i44dSTGqbMycHF7zbA/s4032/IMG_6586.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3wvYuFnn-Cb4diEbNGWrvVHxbwrMtC-iAbsWD-IGnVp-4xESQtGwBqBx_Q1SgT6w8GqboiPlkb6sEp_4W9b4Di0NzSvFWyRxLXIf4fqaUhplVrvuRIlvVGsdrbVyYy_x9urs7Gx5fvR7Mcc62BuXrX1FtGJohoRyZmYe6i44dSTGqbMycHF7zbA/w400-h300/IMG_6586.JPG" width="400" /></a></div> ....as were each of the pistons, that were then dropped in.</span><span style="font-family: arial;"> These go in with the nipple end facing out of the hole.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKlLv3VWn6v6m5d1fwCO4Q6Fx3EVX-WUzBDCcD2fTwLn0HSXC7Uklv_S84p6QFeHB0LaifEYyw0YenkZ9QLbgGSjfAQ6tNd6ZncQgEj6TIVKNp7mBq-ST6lktQ0CtLtSNzrrhQATgRyAD2Key9y4xseAkv3DprF13tqJxDfZUfUfwuP1mRm4-_mA/s4032/IMG_6585.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKlLv3VWn6v6m5d1fwCO4Q6Fx3EVX-WUzBDCcD2fTwLn0HSXC7Uklv_S84p6QFeHB0LaifEYyw0YenkZ9QLbgGSjfAQ6tNd6ZncQgEj6TIVKNp7mBq-ST6lktQ0CtLtSNzrrhQATgRyAD2Key9y4xseAkv3DprF13tqJxDfZUfUfwuP1mRm4-_mA/w400-h300/IMG_6585.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Refitting the gearchange pistons<br /></span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;">Lastly the small cap was replaced. If everything has gone back as it should, the top of the cap will be flush with the face of the shaft.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Now it's time to get back to those syncro pistons and tricky 'O' rings. This time job gets easier as you go along. The first thing to do is to refit the auxilary clutch control slide valve. This was lubricated and carefully dropped into the shaft. It slid in with a satisfying 'slurp'.The valve has a little circlip right at the end that stops it sliding all the wat through. It just sits at the bottom of the shaft, where it narrows, beneath the syncro pistons.</span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">Next in goes one of the new 'O' rings. Lubricated with LHM, these can be manipulated in with a finger. Avoid the temptation to use anything sharp to get them to sit in the grooves. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMizztdhw8EMS4zgzaRHgbybXcBY6xKDpa5zcRbS7lSKNvh8RuIFhw-Wgw99BjS4uFm1c4Ly8Ss0_I2ZGzwY2RxffoeyebMjr90DU3bLw7XAuZHOvxL7P-YNWR4OEK8oxvz5mhOfgQsWouyOx4g4ZBRni5b9Ws3NGg1fhsgbk9efdKVcuX_HRHcw/s4032/IMG_6595.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMizztdhw8EMS4zgzaRHgbybXcBY6xKDpa5zcRbS7lSKNvh8RuIFhw-Wgw99BjS4uFm1c4Ly8Ss0_I2ZGzwY2RxffoeyebMjr90DU3bLw7XAuZHOvxL7P-YNWR4OEK8oxvz5mhOfgQsWouyOx4g4ZBRni5b9Ws3NGg1fhsgbk9efdKVcuX_HRHcw/w300-h400/IMG_6595.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">'O' ring for the syncro piston shaft</span><br /></td></tr></tbody></table>Next in goes a syncro piston. The last one you removed, should be the first one to go back in etc. Lubricated with LHM, the piston will slide down the shaft and sit on the rim of the new 'O' ring. It needs to be encouraged to go further.....I selected along depth socket that sat comfortably on the piston - but which was not so large that it would touch and damage the shaft walls.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhothaneLQ9TdQE0Ly1YlUAphZsbdV1LWLrKjHEAD0TApw9KW1NSiTATcdmfQOuDgebbN5sZ1Yl_OX3Stz5qZXHbCCixzO3kLdZZ-utw2gdhLZ-fBff4TE9WYnEx40s9pheOzc0zVaOtfH-yVpcZyTgoUjTkyr292NAX_tA48fbY7b8CE2jbw9NXA/s4032/IMG_6594.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhothaneLQ9TdQE0Ly1YlUAphZsbdV1LWLrKjHEAD0TApw9KW1NSiTATcdmfQOuDgebbN5sZ1Yl_OX3Stz5qZXHbCCixzO3kLdZZ-utw2gdhLZ-fBff4TE9WYnEx40s9pheOzc0zVaOtfH-yVpcZyTgoUjTkyr292NAX_tA48fbY7b8CE2jbw9NXA/w300-h400/IMG_6594.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Selecting a socket to help refit the syncro pistons</span><br /></td></tr></tbody></table></span><span style="font-family: arial;">The pistons have a bevelled edge to help things along. </span><span style="font-family: arial;">I found that a generous brush of LHM on the fitted seal and when putting the piston in, meant that I only needed to give a couple of gentle hammer taps to persuade the seal to yield and let the piston past. It was obvious when this happened and I stopped tapping. I continued with another 'O' ring and then another piston and gradually the stack built up - with lots of LHM to help things along the way.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcyuDgiZFElzAbAwlFDQtsa8LWh8u4LkuFzRoeHqFnWydrLSpXtvP4uPTxjb63msHkltVdHpVP8Vdvcyf0NXUy_bUqqpyljsMsc4dpeC8L0sJnf1H4NDjsXQbUKdEzvdGejJOKb3eqdPLg_cNO2HpkCzhukfgSsJAEECRvyBEDTDrvpPQKT7yqJQ/s4032/IMG_6597.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcyuDgiZFElzAbAwlFDQtsa8LWh8u4LkuFzRoeHqFnWydrLSpXtvP4uPTxjb63msHkltVdHpVP8Vdvcyf0NXUy_bUqqpyljsMsc4dpeC8L0sJnf1H4NDjsXQbUKdEzvdGejJOKb3eqdPLg_cNO2HpkCzhukfgSsJAEECRvyBEDTDrvpPQKT7yqJQ/w400-h300/IMG_6597.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Can you see the tip of the piston?</span><br /></td></tr></tbody></table><br /><span style="font-family: arial;">If everything has gone as needed, the rim of the last piston should be flush with the rim of the shaft. Like this.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhy5PaluzF5JbO9-1daFcueuRBJitbpgHrN2trFJJI_BetzyKnAtVhUZmpwlo_yebv0FcWSsYZsk89vMPL4mc0N7g4YhUtQhijqbILevZkUUQbuT9RHE9v_3CXfFr4uwz_fgO47t2B_1PLVP9p52mpquaXB1R3v_YxIFl1YtDpHRjAoBPy2JiPMJQ/s4032/IMG_6602.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhy5PaluzF5JbO9-1daFcueuRBJitbpgHrN2trFJJI_BetzyKnAtVhUZmpwlo_yebv0FcWSsYZsk89vMPL4mc0N7g4YhUtQhijqbILevZkUUQbuT9RHE9v_3CXfFr4uwz_fgO47t2B_1PLVP9p52mpquaXB1R3v_YxIFl1YtDpHRjAoBPy2JiPMJQ/w400-h300/IMG_6602.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The last piston refitted</span><br /></td></tr></tbody></table><span style="font-family: arial;">The gear selector valve can be replaced.......</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfP0Q2ruyouMUJQpPSIZ4YR7VtMnqsQSxJldcbbUqdFjWRjdC1PPR4aDqy_257nokKa1cGCOQNpUIh3RwjSNfWuPLZ8t9FZvNIevSnGl7g4wAutimSZ5iUOYqAyWZbpfbGgbr2AzCoEKNW41ME850a1HLptWVOFQTNE3fa8pLtZqdFUz9WkVsL6g/s4032/IMG_6605.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfP0Q2ruyouMUJQpPSIZ4YR7VtMnqsQSxJldcbbUqdFjWRjdC1PPR4aDqy_257nokKa1cGCOQNpUIh3RwjSNfWuPLZ8t9FZvNIevSnGl7g4wAutimSZ5iUOYqAyWZbpfbGgbr2AzCoEKNW41ME850a1HLptWVOFQTNE3fa8pLtZqdFUz9WkVsL6g/w400-h300/IMG_6605.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Refitting the gear selector slide valve<br /></span></td></tr></tbody></table>.....and then it's on to the home straight.</span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">The last parts to fit are the springs and their thrust washers. An important point to note here is that, as the springs are compressed, the shank of one washer is presed into the body of the other. Citroen recommend that you check these for 'free play' to make sure they do not snag on one another and prevent normal operation of the gear brain.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHqBwIfuvasjKcKWyjMDVEcMGlNzdpbr688xtG_WvVSRpArQplVVrKxgFwnMi4O08VlaIpYZUu4TtPQc7nqbHuI4Ks_S0ighIKDDxf7ZkFzHZqUgxAeUdwYJ3GoSV4_ADFi_wnvf3XxSul3K0t4_e0cgNa7ZUTymnu9ixCw4rK4wdJvRtQKSlgTw/s4032/IMG_6530.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHqBwIfuvasjKcKWyjMDVEcMGlNzdpbr688xtG_WvVSRpArQplVVrKxgFwnMi4O08VlaIpYZUu4TtPQc7nqbHuI4Ks_S0ighIKDDxf7ZkFzHZqUgxAeUdwYJ3GoSV4_ADFi_wnvf3XxSul3K0t4_e0cgNa7ZUTymnu9ixCw4rK4wdJvRtQKSlgTw/w400-h300/IMG_6530.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">The spring thrust washers fit together under compression</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">The other important point to note is that the shank of the thrust washer for the body end of the assembly (the 'male' thrust washer if you will) has a hole in it.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoE9xdy9SzCV6D5gvfdvtajgFcfPjaU36emGPdAR5d0Ww845tloU7DXPQOUnovthNzq4XrdOEEde3ADJx6RmsmPrVOTGvqo7etiCHkqK381VjPP3lkJ7kMyQbDJ8p5Xe8yb6_Ct_64MRkWcjF8xCkOLyN9vitgUb6YtFL8YSrxtSdnssqHzZ-Nbw/s4032/IMG_6603.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoE9xdy9SzCV6D5gvfdvtajgFcfPjaU36emGPdAR5d0Ww845tloU7DXPQOUnovthNzq4XrdOEEde3ADJx6RmsmPrVOTGvqo7etiCHkqK381VjPP3lkJ7kMyQbDJ8p5Xe8yb6_Ct_64MRkWcjF8xCkOLyN9vitgUb6YtFL8YSrxtSdnssqHzZ-Nbw/w300-h400/IMG_6603.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Note the hole through the thrust washer</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">The repair manual says that, when the spring assembly is fitted, it should be orientated so that this hole is 'towards the bottom' when everything is fitted back on the car. I took this to mean the hole should face down towards the ground and so took a few moments to work out what was the top and bottom of the gear brain when fitted. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvbEf2dkRTD9y86KBA3crE0rJQW1DZn9rNRELgF3KuvgqnrqxW18RJ3TkgYpX75nexcb9hy63Fq6EsXAkPnq7mA0N-o0YGGxBkEMkeDHqf0fMqhqcn_I7YbPh4_A8eq5zym6G_UYi8ysSMKNGm3MxUji9j_VT34dvqfwY4T_pq2wOXTaFngu8p1Q/s4032/IMG_6604.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvbEf2dkRTD9y86KBA3crE0rJQW1DZn9rNRELgF3KuvgqnrqxW18RJ3TkgYpX75nexcb9hy63Fq6EsXAkPnq7mA0N-o0YGGxBkEMkeDHqf0fMqhqcn_I7YbPh4_A8eq5zym6G_UYi8ysSMKNGm3MxUji9j_VT34dvqfwY4T_pq2wOXTaFngu8p1Q/w400-h300/IMG_6604.JPG" width="400" /></a></div>With that clear, the spring assembly was appropriately put in place and a new gasket added.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidJpauhvsyT33mex7bj-uBcIo54Ad8ZKrD3NgHl0YJIGlpzcwKAFNctXRiivBwI7UTHkIUBiZR5smIew1gBJ0jbd4Ymghgh75q0ZmnkcpMdiPgiv70XKaRB_fSMkrhNnowcHohVOF4ljlAn6tGPt3OQMCcp7Q8GVjhP12rCx8gE02r62ZGSys-qg/s4032/IMG_6609.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidJpauhvsyT33mex7bj-uBcIo54Ad8ZKrD3NgHl0YJIGlpzcwKAFNctXRiivBwI7UTHkIUBiZR5smIew1gBJ0jbd4Ymghgh75q0ZmnkcpMdiPgiv70XKaRB_fSMkrhNnowcHohVOF4ljlAn6tGPt3OQMCcp7Q8GVjhP12rCx8gE02r62ZGSys-qg/w400-h300/IMG_6609.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Nearly done......</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">The cover was carefully pressed-on - against the pressure of the springs - and the nuts wound on by a part turn. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinelkvbjpCWD5AQbeH1-qH6gIQZ5JuHWjmnKvuuP3lxUk9GlzTknUTeVJt-SZh9Wk4E4iZTpW9eXu-cnJvc21xxpNpkZODQvC8K1X_Pi4LGOOkzFyMUtjaB_FT7UJmQ_4x6Ss6JklIe4B2LJx6Op666vIov-Re0TzyrOY7MMYt9R8FUfOufVK-vQ/s4032/IMG_6612.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinelkvbjpCWD5AQbeH1-qH6gIQZ5JuHWjmnKvuuP3lxUk9GlzTknUTeVJt-SZh9Wk4E4iZTpW9eXu-cnJvc21xxpNpkZODQvC8K1X_Pi4LGOOkzFyMUtjaB_FT7UJmQ_4x6Ss6JklIe4B2LJx6Op666vIov-Re0TzyrOY7MMYt9R8FUfOufVK-vQ/w400-h300/IMG_6612.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Refitting the front cover</span><br /></td></tr></tbody></table>I gradually added the bolts and gave each nut and bolt a small tighten in sequence - much as you would the nuts when fitting a wheel - until the cover was uniformly tightened down.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">And that seems a convenient point to leave things. In my next post I will tackle the 'gearchange speed regulator' by which I mean the 'viscosity compensator' of course.<br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-78381600117269149182023-03-03T20:26:00.000+00:002023-03-03T20:26:11.415+00:00Steering Relays - Strip Down and Overhaul<div style="text-align: justify;"><span style="font-family: arial;"> I finally got round to finishing the rebuild of the steering relays.</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnAtUN0yHiaHRql_IAdzHvGlCyobWTEl6p0ggcY9xevKHiQaEiBOARKZB5sc4qmt1fTGyapjEjqAAGc3SiJL17WzP-js6g2KB7rY4FFx-YpwQ_4Pv7PBZVme56DRaZIavtIrp5UclYCu2xUyFBJBXz77RxSotsl7FdG-p_rf44F864h4wvCNAbMQ/s4032/IMG_6083.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnAtUN0yHiaHRql_IAdzHvGlCyobWTEl6p0ggcY9xevKHiQaEiBOARKZB5sc4qmt1fTGyapjEjqAAGc3SiJL17WzP-js6g2KB7rY4FFx-YpwQ_4Pv7PBZVme56DRaZIavtIrp5UclYCu2xUyFBJBXz77RxSotsl7FdG-p_rf44F864h4wvCNAbMQ/w400-h300/IMG_6083.JPG" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">The steering relays help to transfer the movement of the steering rack to the pivot/ hub assemblies. The steering rack arms connect to the splined tops of the relay arms. The bottom cranked ends of the relays are connected to the pivots by a pair of arms and ball joint assemblies.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhL6US_aBdTxqPj4FSOcLTd5c5Md1Pe3SDmLBwYXbUDx8lNrVpsLdEyDF-0L124LBC5d2Vi6ejUtNRK-xFkGM0AGequdrsjRKgB3kf2jjY3lrPGkfS930dvongFmQHCmLBgWoVcnWbjJxOyNeq_CeT_B95Mc9OzllVzBDh35DnQw6O5EGiDvx6C7g/s976/steering.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="734" data-original-width="976" height="301" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhL6US_aBdTxqPj4FSOcLTd5c5Md1Pe3SDmLBwYXbUDx8lNrVpsLdEyDF-0L124LBC5d2Vi6ejUtNRK-xFkGM0AGequdrsjRKgB3kf2jjY3lrPGkfS930dvongFmQHCmLBgWoVcnWbjJxOyNeq_CeT_B95Mc9OzllVzBDh35DnQw6O5EGiDvx6C7g/w400-h301/steering.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Steering relay parts<br /><br /></span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The procedure for removing the relays</span><span style="font-family: arial;"> can be found at Operation DX.443-1 in manual 518. It isn't in Manual 814 as printed, but may have been added into some pdf copies of the manual from Manual 518. If so, it's in section 1 ('Removal and Refitting') in Volume 2. </span><span style="font-family: arial;">It's a similar story for the procedure for stripping and rebuilding the relays. You can find it at Operation DX.443-3 in manual 518, and those pages might be in some pdf copies of Manual 814.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div><div style="text-align: justify;"><span style="font-family: arial;">Because of the job they do, the bottom ends of the relays - down in the wheel arches - are quite exposed to rain and dirt. I'd started to remove and strip the relays back in May 2021. As well as being dirty and rusty, with the steering rack removed and the hubs linkages disconnected, I'd discovered that the relays</span><span style="font-family: arial;"> were quite 'knotty' and didn't move smoothly. </span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPfnHnpzu76sdAiOgr1N0sdrJVkX1DZ9e0D1JR81jLI0iyHHers_z9XLH-cbEIiJviUbWzJzI3kKs61ze_09AYAOBRMw4C43LzdDbld51Jtiq5NV0gCWhAEtel5458KRS4qFQURn2eNagLGQiMjeZbWe8l1RFoU_qyUlBdbEjGj5XAM_LLGyWoFg/s3264/steering%20arm2.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPfnHnpzu76sdAiOgr1N0sdrJVkX1DZ9e0D1JR81jLI0iyHHers_z9XLH-cbEIiJviUbWzJzI3kKs61ze_09AYAOBRMw4C43LzdDbld51Jtiq5NV0gCWhAEtel5458KRS4qFQURn2eNagLGQiMjeZbWe8l1RFoU_qyUlBdbEjGj5XAM_LLGyWoFg/w400-h300/steering%20arm2.JPG" width="400" /></a></div><span style="font-family: arial;"><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div>The relays are held to the chassis by a large bolt passing horizontally through the chassis arm. </span><span style="font-family: arial;">The nuts on these are a real bugger to undo! Firstly they are on the wheel side of the chassis and so rust and seize on the bolt. Secondly the 'bolt head' ends are unconventional. In fact at first I </span><span style="font-family: arial;">didn't even realise they were bolt heads until someone explained what I was seeing to me. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCv--FOS_3zWT_oW8lxIMW5bo38QeNRa7DbZ3hw2xdUG0WKa7hPoK5ouSBWuCSQ6a4-wCKm-zR-ydgrpgUTa0eYjCvlpqKrH0PF8h2RFEsZr2htFgRu2ul_s5d3Ej9XZ09ZneA3-Hora7g4Rw7QbBS36Ub92kjzvwppOT5h4GQCP1zNxwWdgHqHg/s4032/IMG_6280.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCv--FOS_3zWT_oW8lxIMW5bo38QeNRa7DbZ3hw2xdUG0WKa7hPoK5ouSBWuCSQ6a4-wCKm-zR-ydgrpgUTa0eYjCvlpqKrH0PF8h2RFEsZr2htFgRu2ul_s5d3Ej9XZ09ZneA3-Hora7g4Rw7QbBS36Ub92kjzvwppOT5h4GQCP1zNxwWdgHqHg/w400-h300/IMG_6280.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Bolt head of the relay arm bolt<br /><br /></span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The bolts are hollow. Rather than being hex-headed, they have only two, shallow, flat edges. To complicated things further, the heads are recessed into deep washers or spacers - that's washers on the bolt end, not the nut end - meaning little of the heads remain exposed.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk_P6RbmmqgBYBRaf43ZwioU9mZk3GGNYjo5kEYzoonBhYcleHiukMBf2z92xsawRA8QlT20jiewJ-xsWQvGttYWcsIthCpP8Syzc8AUOvWLqXJHA5XtxZx50MkMOBWFEb8ecQdZdQSV-Cz8tzvMd0uepUplQnB6S0hgfL40-4IUHCdM3LW6tx0w/s4032/IMG_6282.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk_P6RbmmqgBYBRaf43ZwioU9mZk3GGNYjo5kEYzoonBhYcleHiukMBf2z92xsawRA8QlT20jiewJ-xsWQvGttYWcsIthCpP8Syzc8AUOvWLqXJHA5XtxZx50MkMOBWFEb8ecQdZdQSV-Cz8tzvMd0uepUplQnB6S0hgfL40-4IUHCdM3LW6tx0w/w400-h300/IMG_6282.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Washer (or more accurately spacer) on the relay bolt<br /><br /></span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">All in all it means that there is a risk of rounding the straight edges of the head when you try to undo the nuts. I soaked mine in penetrating oil occasionally before I tackled them and proceeded cautiously. In the end it was pretty straightforward to remove them.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">The relays are able to pivot/ be rotated to some degree around this large central bolt, and so are fixed in position by smaller bolts that hold the heads down to the chassis arms. When I removed these smaller bolts I found a number of spacer washers.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjiiuEifqJ4sxkB3pI-1kiBFkU88WS_KrVBVvRR1jfGcM9t73WJ8U7seqjuU4pC_PUli50kZ1TbD_mBfGcVd8Fx8RZBLL_sNL4UMbCMS3tjEJCAMaF5-nXh_iErlsNrydOpuMqKogSe8sqy9ST4Kr9CSRjkNduQUFQCXvY8dtqH7dF7gvDvk2Bgw/s4032/IMG_2908.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjiiuEifqJ4sxkB3pI-1kiBFkU88WS_KrVBVvRR1jfGcM9t73WJ8U7seqjuU4pC_PUli50kZ1TbD_mBfGcVd8Fx8RZBLL_sNL4UMbCMS3tjEJCAMaF5-nXh_iErlsNrydOpuMqKogSe8sqy9ST4Kr9CSRjkNduQUFQCXvY8dtqH7dF7gvDvk2Bgw/w400-h300/IMG_2908.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The spacer washers are in the middle of the photo</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">These are spacers that pack out the space between the lug on the side of the relay and the chassis.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg07gkiIbVDIv1Q-figd3tQ8X_lnF9Lix6bwsgDMZGyTMuec7Xe-jR0CeU8xUKIqi39ug5GBO-zc0daPVAEffFtxyDCPZ1fCk7up7Io39ughMzEyaK7CzO78IV_47PkuefpS0-cKkzlwnCgmYz5-qtusu5MiEqfKKJIG9zqMdtUTJyb0MZeUQaYeQ/s4032/IMG_2907.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg07gkiIbVDIv1Q-figd3tQ8X_lnF9Lix6bwsgDMZGyTMuec7Xe-jR0CeU8xUKIqi39ug5GBO-zc0daPVAEffFtxyDCPZ1fCk7up7Io39ughMzEyaK7CzO78IV_47PkuefpS0-cKkzlwnCgmYz5-qtusu5MiEqfKKJIG9zqMdtUTJyb0MZeUQaYeQ/w400-h300/IMG_2907.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Spacing washers under the relay mount</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">It's all to do with the correct angle of the relay.</span><span style="font-family: arial;"> </span><span style="font-family: arial;">When they are first fitted, a special tool is used to set the alignment of each steering relay.....</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjebmIi7S8DPi2tzIX0sDm5k9a03D0AP7nOy-hCHbmWBib6TYAKcfwUEQe2kCQgjqiCufCcwJ-yAb-QWY855UGP2VHIvNg6XJbXmiwUD7szWG6PVy62klXa3EjyK3fpe3Uq07Ve6UquNizKPaiT9x0KyPBhJaKtHWLPnXBffVt6S8xndMEntm2Ohw/s1420/241781588_899605260941715_8660101803410863852_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="640" data-original-width="1420" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjebmIi7S8DPi2tzIX0sDm5k9a03D0AP7nOy-hCHbmWBib6TYAKcfwUEQe2kCQgjqiCufCcwJ-yAb-QWY855UGP2VHIvNg6XJbXmiwUD7szWG6PVy62klXa3EjyK3fpe3Uq07Ve6UquNizKPaiT9x0KyPBhJaKtHWLPnXBffVt6S8xndMEntm2Ohw/w400-h180/241781588_899605260941715_8660101803410863852_n.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Use of tool 1995-T too align the relay.<br />(photo credit unknown)</span></td></tr></tbody></table></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">The relay is rotated slightly until the pin engages in the dimple in the arm.......</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgiyiuVyIjKbcMEID3HIPNAZtb_2XFSt4KJcdkwanCCPklC5w-eqdpvryZwDqo7p1bbeysIQl2SHTzvjiLpW2T3MYKpe1U79S1_DaU3AxXPjeS0_WSxhAgA3SVclP0X6Q0t0-Jdptmh0339oXOtfG73CfINyYkAOwPvh6v2BV10TRJEPBFXqi6-g/s640/241681568_4090337924410791_6308969139728534895_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgiyiuVyIjKbcMEID3HIPNAZtb_2XFSt4KJcdkwanCCPklC5w-eqdpvryZwDqo7p1bbeysIQl2SHTzvjiLpW2T3MYKpe1U79S1_DaU3AxXPjeS0_WSxhAgA3SVclP0X6Q0t0-Jdptmh0339oXOtfG73CfINyYkAOwPvh6v2BV10TRJEPBFXqi6-g/w400-h300/241681568_4090337924410791_6308969139728534895_n.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Engaging the pin in the arm - more spacers needed!</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">......and then a combination of different thickness spacers is used to pack out any gap.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizsNn0qpH17Q_vgUNC0UaX9rL2RSM0ovNGWPYjYqByRF1vLaaPWSImSfXf8iFJZ0EgOzzydD786WtXNA3ETuT23HYJ5uinnR4WuKA5NOOSzf2ATkojaF2zshGayEHN4YvgxpSJN_xEpoU41FVvxiqldvdbIie6gCeMz7RHtg2oZX6Nm9J0dphZzQ/s640/241683842_4090338571077393_5084887797946070050_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizsNn0qpH17Q_vgUNC0UaX9rL2RSM0ovNGWPYjYqByRF1vLaaPWSImSfXf8iFJZ0EgOzzydD786WtXNA3ETuT23HYJ5uinnR4WuKA5NOOSzf2ATkojaF2zshGayEHN4YvgxpSJN_xEpoU41FVvxiqldvdbIie6gCeMz7RHtg2oZX6Nm9J0dphZzQ/w400-h300/241683842_4090338571077393_5084887797946070050_n.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">That's better...</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I'm guessing all this is necessary because of slight differences in the construction of the chassis or differences in the machining of the relays - or maybe a bit of both. There could be a different number of spacers used on each relay - so keep them all, and don't muddle the relays up!</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">With the relays removed I set about dismantling. And things started to go wrong almost immediately. To stop it loosening, the edge of the threaded upper nut is peened over into a groove in the main body. </span><span style="font-family: arial;">I used a drift to bend that peened edge back in away from the relay body. I did that to both nuts.</span><span style="font-family: arial;">The upper nut needs a special tool to remove it. The tool needs to fit over the splined end of the arm and have four 'pins' that lock intro hole in the nut.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOCvbYhBSWntGOzojj-Ka7FgLByyKR5aNY-ggGEwLZmKgNAmN7XzTGHaCnBikjTko-VuX_sCiohEaMhiT8cO9wzmWqBRs8lQauL1wGb6AU8fYRFQ29VWYOz55qN_2FC69uve-Ub5ybIcnHWk90k4EnTg75wcF961_zsck1d9R28LOSkqTUkvtZ0g/s4032/IMG_6060.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOCvbYhBSWntGOzojj-Ka7FgLByyKR5aNY-ggGEwLZmKgNAmN7XzTGHaCnBikjTko-VuX_sCiohEaMhiT8cO9wzmWqBRs8lQauL1wGb6AU8fYRFQ29VWYOz55qN_2FC69uve-Ub5ybIcnHWk90k4EnTg75wcF961_zsck1d9R28LOSkqTUkvtZ0g/w400-h300/IMG_6060.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Relay nut. Note the peened edge at the bottom<br /><br /></span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The tool can then be rotated to loosen the nut. That's the theory at least. </span><span style="font-family: arial;">I fashioned a crude tool out of an old socket with four pins welded around it's circumference and tried to use a ratchet to loosen the nut - but it wouldn't budge without using considerable force and several repairs to my home made tool. It was heavy going with the noise and feel of metal grinding on metal. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixzT8z5Wc0DS2716_VQZ1x8VLn7ASo2nPcxK3mK8lWLZcOPjsuisNSHNloobJOPxZeBJb6iKmdjbs-QCyxt-aZz9GyrHzO8zEv2Z7bmd47iz3FgXckA1ot3eegYl6_dLuYzNtfrBPvI0gr6HRGrkD-0j4rgMN15oIC44T9WttPcbs8ly2Q-rU6OA/s4032/IMG_2918.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixzT8z5Wc0DS2716_VQZ1x8VLn7ASo2nPcxK3mK8lWLZcOPjsuisNSHNloobJOPxZeBJb6iKmdjbs-QCyxt-aZz9GyrHzO8zEv2Z7bmd47iz3FgXckA1ot3eegYl6_dLuYzNtfrBPvI0gr6HRGrkD-0j4rgMN15oIC44T9WttPcbs8ly2Q-rU6OA/w400-h300/IMG_2918.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Daylight outside, but truly in the 'heart of darkness' now.....</span><br /></td></tr></tbody></table><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I soon realised what the problem was: the nut threads had been damaged by the peening (and my bashing?) and were out of alignment - squashed or misaligned in some other way. My efforts at removing the nut were probably damaging the threads on the body too. With the nut half in and half out, I had no option but to try and press on. The nut fought me every fraction of a rotation. I used heat. I used oil. I used brute force. My workbench looked like a battlefield. And this was only the first relay! Eventually the titanic battle was over and slowly but surely the nut was removed. </span></div><div style="margin-left: auto; margin-right: auto; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjayKPuaZvJPFQhHI7XUJGCsIrgrBdwTvkXmHHRVhZu17YsUw6ymEEPDxGD8R7aBJjmSYGrjAhK9ihFD-HA7Os3HX-gdPX0NPPt_7E3AjO8zEO4k98j5yP2u5VMiWsHTBpCacI3utf5JGBHsiZLhunLYeYx9gqMtGHqk4SqZ_9SF66hiH0UBjOuYg/s1028/groove.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="769" data-original-width="1028" height="299" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjayKPuaZvJPFQhHI7XUJGCsIrgrBdwTvkXmHHRVhZu17YsUw6ymEEPDxGD8R7aBJjmSYGrjAhK9ihFD-HA7Os3HX-gdPX0NPPt_7E3AjO8zEO4k98j5yP2u5VMiWsHTBpCacI3utf5JGBHsiZLhunLYeYx9gqMtGHqk4SqZ_9SF66hiH0UBjOuYg/w400-h299/groove.jpeg" width="400" /></a></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I tried to set my worries aside and I </span><span style="font-family: arial;">set about dismantling the relay. I was 'in the zone' and didn't bother to refer to the manual. With the nut removed, the arm had some freedom of movement in the body and the balls were dislodged from their bearing cups. With a bit of effort I was able to knock the arm out through the body. </span><span style="font-family: arial;">With it came some of the balls. The others remained glued inside the body with sticky, dirty grease.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">With the top nut and relay arm removed, from the top end of the relay body I was able to winkle out the dished thrust washer, the top bearing cup and the top oil seal.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><div style="font-family: -webkit-standard;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIIJKZLYSEC2Ikfd4szrERqHZuh_Ar1wPG7GuGQ6nkjqwIQQtBEEavXCPX43w4HNCJwKLCtMOS_U_HC2kieKN0FkZDp-uVTVw42ysOQ3pPL1gwHf_zkRA6AxReJYJr-tDHd1pwyIK4zGfLE04bMd9r0SReEYYLACwUxi_fgUaDhs9a221OTp4DHQ/s4032/IMG_2913.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIIJKZLYSEC2Ikfd4szrERqHZuh_Ar1wPG7GuGQ6nkjqwIQQtBEEavXCPX43w4HNCJwKLCtMOS_U_HC2kieKN0FkZDp-uVTVw42ysOQ3pPL1gwHf_zkRA6AxReJYJr-tDHd1pwyIK4zGfLE04bMd9r0SReEYYLACwUxi_fgUaDhs9a221OTp4DHQ/w300-h400/IMG_2913.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The top oil seal is beneath the bearing cup</span></td></tr></tbody></table></div><div style="font-family: -webkit-standard;"><br /></div></span></div><div style="text-align: justify;"><span style="font-family: arial;"><div style="font-family: -webkit-standard;"><span style="font-family: arial;">On the bottom, cranked arm, end of the relay is a protective metal dust cap. </span><span style="font-family: arial;">That was carefully levered off to reveal an oil seal. </span><span style="font-family: arial;">That was prised out and, beneath all the rusty grease, was a </span><span style="font-family: arial;">circlip......</span></div><div style="font-family: -webkit-standard;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhksOAgdcIAEDzCnVxFgcHjCoSWpyaXxXX5Y0fM6KJ9tgHTU8tZXm9juQc9vCAgCHuzLUvrKkxgZ9xuA5fGhFluRu_6gihI5o2pz02Yyra1UECZ5kZxz0vdSk7p8SQWf32vDT55ZkPcldzQSInGXNpXFo1S8WmGg2QZmPS3jbcnEW3R6fujN-4hIw/s4032/IMG_3152.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhksOAgdcIAEDzCnVxFgcHjCoSWpyaXxXX5Y0fM6KJ9tgHTU8tZXm9juQc9vCAgCHuzLUvrKkxgZ9xuA5fGhFluRu_6gihI5o2pz02Yyra1UECZ5kZxz0vdSk7p8SQWf32vDT55ZkPcldzQSInGXNpXFo1S8WmGg2QZmPS3jbcnEW3R6fujN-4hIw/w300-h400/IMG_3152.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The circlip secures the bottom bearing cup</span><br /></td></tr></tbody></table><br /></div><div style="font-family: -webkit-standard;"><span style="font-family: arial;">The circlip holds the bottom bearing cup in place. The arm bearing race - and so arm - is locked in position by that bearing cup but, with the circlip removed, the arm can be carefully tapped down and out. At this point I wished I'd referred to the manual!</span></div><div><span style="font-family: arial;"><br /></span></div></span></div><div style="text-align: justify;"><span style="font-family: arial;">All the grease and stray balls were scooped out of the body. The parts were cleaned and accounted-for before I examined them. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKyq5xsGsNaRd5FhQNICNREqAZiLk6_aVisjWG80R-yjXPrilyZ1q6XlyVCo7xOtf6KlYntQGFror66TMkZPMC5pGnPuQIjqM8c5GVWMr4TsGhwiYsvvQtguApJKIRVOCZ5qICUPX6vgF_0WZbWz-7x0ce7Q54OlIWGA8rOCVtByuUF49m85QiHQ/s4032/IMG_2923.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKyq5xsGsNaRd5FhQNICNREqAZiLk6_aVisjWG80R-yjXPrilyZ1q6XlyVCo7xOtf6KlYntQGFror66TMkZPMC5pGnPuQIjqM8c5GVWMr4TsGhwiYsvvQtguApJKIRVOCZ5qICUPX6vgF_0WZbWz-7x0ce7Q54OlIWGA8rOCVtByuUF49m85QiHQ/w400-h300/IMG_2923.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Relay arm dismantled</span></td></tr></tbody></table></div><div><br /></div><div style="text-align: justify;"><span style="font-family: arial;">Unfortunately several came up wanting.....On one relay, one of the bottom bearing cups was pitted in places.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrIUoZMZyJAbKXuRGRYDvOXfVICNk82WnAETISJxjQZ_YkV3CIktAcILE8hegxodKIan9VBIE2_BOTb4QvSAYQy-yOZWDO3JB0nunZETzGKlbtRc1rhGNmM_bF8JSr-fIe4Vcf7mGlxUxF-qFdt-F8zOl30xVRl2PAj86NA857muhFgq4kjdnqaQ/s4032/IMG_6076.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrIUoZMZyJAbKXuRGRYDvOXfVICNk82WnAETISJxjQZ_YkV3CIktAcILE8hegxodKIan9VBIE2_BOTb4QvSAYQy-yOZWDO3JB0nunZETzGKlbtRc1rhGNmM_bF8JSr-fIe4Vcf7mGlxUxF-qFdt-F8zOl30xVRl2PAj86NA857muhFgq4kjdnqaQ/w400-h300/IMG_6076.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Pitted old bearing cup - and a new replacement</span><br /></td></tr></tbody></table><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">On the other relay, one of the ball channels in the arm itself was pitted.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLaj233jsMLMTKsjs2maTUc6BWX1oas0NIt1Sl11NxLy-1xkkut4wArfnTEykzWoRbOEy-lQSVGG2osWxbv_VaXgQUGWCOnJUPV7cH7YEFgP3i73YqIdpddH16uQ7-baF_ouwUfH16hT9wYgRStrNW01q1RhuOj9WMKV2h8R9YFgfgLcUX7GCH5w/s4032/IMG_2921.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLaj233jsMLMTKsjs2maTUc6BWX1oas0NIt1Sl11NxLy-1xkkut4wArfnTEykzWoRbOEy-lQSVGG2osWxbv_VaXgQUGWCOnJUPV7cH7YEFgP3i73YqIdpddH16uQ7-baF_ouwUfH16hT9wYgRStrNW01q1RhuOj9WMKV2h8R9YFgfgLcUX7GCH5w/w400-h300/IMG_2921.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Pitting damage to the bearing groove</span></td></tr></tbody></table></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">In both cases I think this was down to water penetration and rust. </span><span style="font-family: arial;">Before I pressed-on with a rebuild I needed to know whether these relays could be salvaged. I used a file to try and dress the damaged threads on the nut and the body but the nut was still reluctant to fit back on without cross-threading. </span><span style="font-family: arial;">Once again, Peter 'Badabec' Bremner came to the rescue. A friend of Peter's had put the correct thread on a large piece of metal and I was able to run that up and down the relay body, like a heavy-duty tap, to clean up the threads.</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1Gz_4wYdDZIzFP98CPHUtOxwWsrVqkQIIFv3Xn28DPkaCWpSfdb-5pJxZrPPw7Rnn-r-wVCMTjjGtiG4YPuE-XsWfG7AA-_7Duh0tvXjnemte0IknskzAH3jvsgpOhqrhUz4fWozqPKbJqK_7RU51Xcj4MPnqPRhVvEd1PxJX_nV7kgmhY2YJgg/s4128/IMG_20210524_164622.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3096" data-original-width="4128" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1Gz_4wYdDZIzFP98CPHUtOxwWsrVqkQIIFv3Xn28DPkaCWpSfdb-5pJxZrPPw7Rnn-r-wVCMTjjGtiG4YPuE-XsWfG7AA-_7Duh0tvXjnemte0IknskzAH3jvsgpOhqrhUz4fWozqPKbJqK_7RU51Xcj4MPnqPRhVvEd1PxJX_nV7kgmhY2YJgg/w400-h300/IMG_20210524_164622.jpg" width="400" /></a></div><br /><span style="font-family: arial;">Peter had also made his own pin tool. Much better than mine.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjua80mK7ZMHT7e5DslzYv7GXzFNsURof_Yx0rbRAu8gPSkeLt2QVIGEcDVpCzcQTF_Xi_FBlUILuwJj8BhUNnmjZk0tixqvE5yVULWzD8zw-iHpYuvBXqLLYXuOMvcLjJ414Y5UJn31zlVwf9XTBFxpIJaYRx42a4dWbgGb4Vq-Bz5FWFyhFs-iA/s4032/IMG_6070.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjua80mK7ZMHT7e5DslzYv7GXzFNsURof_Yx0rbRAu8gPSkeLt2QVIGEcDVpCzcQTF_Xi_FBlUILuwJj8BhUNnmjZk0tixqvE5yVULWzD8zw-iHpYuvBXqLLYXuOMvcLjJ414Y5UJn31zlVwf9XTBFxpIJaYRx42a4dWbgGb4Vq-Bz5FWFyhFs-iA/w400-h300/IMG_6070.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Peter's pin tool came to the rescue</span></span><br /></td></tr></tbody></table></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">With the relay body threads cleaned up and using Peter's tool, I was then able to run the proper nut up and down the body. </span><span style="font-family: arial;">Now knowing that I could at least reassemble the relays, I set about cleaning, painting and acquiring replacement parts.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">By peening the edge over, the top nuts become damaged and really need to be replaced each time you rebuild. </span><span style="font-family: arial;"> </span><span style="font-family: arial;">Peter had </span><span style="font-family: arial;">rebuilt his relays (more on that later) and bought the last two NOS nuts available on Earth. No, really. </span><span style="font-family: arial;">I think he got very lucky there. </span><span style="font-family: arial;">I'd not seen them on sale before, and I've not seen them on sale since. </span><span style="font-family: arial;"> </span><span style="font-family: arial;">The DS parts suppliers sell refurbished units, so perhaps there is a source for replacement top nuts? </span><span style="font-family: arial;">Perhaps it's the kind of part Citrotech sell?</span><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">On the plus side, Peter didn't want the felt dust seals from the botton of his new nuts and very kindly gave them to me. I left them to soak on LHM before fitting them - to give them a water resistant finish.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvzITzDlRe-z6yGsHJJhGjUW8KJSW9X18Z4NL9NVr__uHZk6cr7Q6z0qYvvl5YRckVHzpAFECbahDsmhIV9H4J3itnUdR0NLM6cxHZWs5QzVgXIAFpUcgnypZ-4jeNLumh0fmqgEN6PEXeoQ0Jkk-nPKYnoqKWFRfFycXA1N0Ik5EjfgM2nhTnfA/s4032/IMG_6061.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvzITzDlRe-z6yGsHJJhGjUW8KJSW9X18Z4NL9NVr__uHZk6cr7Q6z0qYvvl5YRckVHzpAFECbahDsmhIV9H4J3itnUdR0NLM6cxHZWs5QzVgXIAFpUcgnypZ-4jeNLumh0fmqgEN6PEXeoQ0Jkk-nPKYnoqKWFRfFycXA1N0Ik5EjfgM2nhTnfA/w400-h300/IMG_6061.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">New felt dust seals</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigBh6L-9LtYneMcC8w7ithuYBYDAAJ-DvsJw0Rh22mA_tKpbU1sLVcIBGL_1KJ7LvSplr520fdOdxcqHmceBW_GDm2sFm6rCA_zPCzoE69326YYefufpk2GH2vFLmruO8sf0TiWOefwp4TtKeLAC41KBa7x3chJsoxSZozklEVwR-UUw1bVgn50g/s4032/IMG_6045.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigBh6L-9LtYneMcC8w7ithuYBYDAAJ-DvsJw0Rh22mA_tKpbU1sLVcIBGL_1KJ7LvSplr520fdOdxcqHmceBW_GDm2sFm6rCA_zPCzoE69326YYefufpk2GH2vFLmruO8sf0TiWOefwp4TtKeLAC41KBa7x3chJsoxSZozklEVwR-UUw1bVgn50g/w400-h300/IMG_6045.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The felt seals fit on the underside of the nuts</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I was able to find a pair of lower bearing cups for sale (these are slightly different to the upper bearing cups), and also sourced some new replacement ball bearings.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinArnEK5X15at226J8IrxWMZ6Oa5o8TNXTVItmCied7DayZf7ts57JWU0KMsPfKUIKmi5OsM8Rhq8msdmE-ekCTvd1XgAEPiysL3VD9yOGBpwS2Om5RSqdWUr08rFaezjh1P49sSS7NPLJtilUhV8XSmFyUnzRhQcGdFxnGUM1HmT6ECpxp4uL3Q/s4032/IMG_6042.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinArnEK5X15at226J8IrxWMZ6Oa5o8TNXTVItmCied7DayZf7ts57JWU0KMsPfKUIKmi5OsM8Rhq8msdmE-ekCTvd1XgAEPiysL3VD9yOGBpwS2Om5RSqdWUr08rFaezjh1P49sSS7NPLJtilUhV8XSmFyUnzRhQcGdFxnGUM1HmT6ECpxp4uL3Q/w400-h300/IMG_6042.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Replacement parts</span></span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">These balls are 7.144mm in diameter (9/32") and widely available. Each relay has two oil seals inside. And they're different. The top seal is "double-lipped". As the name implies, it has a second lip that contacts the shaft within. This is to help provide an additional seal. </span><span style="font-family: arial;">I think, with some hunting, I could have sourced the seals from an oil seal supplier but, for convenience, I bought some from Der Franzose. Initially they sent me the wrong ones (more on that later too!), but I had no problems with an exchange.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">So the top of the relays has a felt dust seal AND a double lipped oil seal. But even that combination didn't seem to stop water and mositure getting inside the relays.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">At this point I was losing interest in the relays - or maybe gaining interest in the next jobs - the suspension arms. That would turn out to be another headache. You can read about that </span><a href="https://ds-restoration.blogspot.com/2022/09/front-suspension-units-replacing.html " style="font-family: arial;" target="_blank">HERE</a><span style="font-family: arial;">.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I painted the relay parts when I painted the suspension arms last summer - more than a year after I'd removed and dismantled them - but then shoved them in a box again for six months while I got on with other things. </span></div><div style="text-align: justify;"><span style="font-family: arial;"> <table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVpHNoHv_qzOZAibGQitvlxVhqhLi6PkWbEVa5Ou2adGJGhQkUdpvmYfzMRR4v8kZTT-Z4UDme1I-hf06WCTk0U8xp0MIjLTTYdDS8aehG-wqa3s_CU9PsfRTR1nL_6wwkNjVQ21cbHI2DYeDzIF26rKOQDj3d1CQ9VLy7bHRV8qeruDx3MF6H1g/s4032/IMG_4959%20copy.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVpHNoHv_qzOZAibGQitvlxVhqhLi6PkWbEVa5Ou2adGJGhQkUdpvmYfzMRR4v8kZTT-Z4UDme1I-hf06WCTk0U8xp0MIjLTTYdDS8aehG-wqa3s_CU9PsfRTR1nL_6wwkNjVQ21cbHI2DYeDzIF26rKOQDj3d1CQ9VLy7bHRV8qeruDx3MF6H1g/w400-h300/IMG_4959%20copy.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Painted parts</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">This year, with the car now coming together, I couldn't delay rebuilding the relays any longer and so recently dug all the parts out. </span><span style="font-family: arial;">I remembered disassembly being a bit of a puzzle (especially as I didn't follow the correct procedure), but re-assembly was very straightforward and it (and I) went by the book. Manual 518 to be precise.</span></div><div style="text-align: justify;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMiV_3GAxo86VGlMj0whRhdvpqAhEmSRoH7lIDVoNMPsIMHH-B0UA--ZTKrtao9dg2o8aQdLQ59bP7ctMz5C2eumMh0lTwM_uE5koFHb8_qQ9G04CU70-kANQ8MFhBnD7zDRS5u6KmtnlmYUawy-5gqE3bItY9kBQrnoCRNWpyZ_6lsWsJRGeaHg/s4032/IMG_6052.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMiV_3GAxo86VGlMj0whRhdvpqAhEmSRoH7lIDVoNMPsIMHH-B0UA--ZTKrtao9dg2o8aQdLQ59bP7ctMz5C2eumMh0lTwM_uE5koFHb8_qQ9G04CU70-kANQ8MFhBnD7zDRS5u6KmtnlmYUawy-5gqE3bItY9kBQrnoCRNWpyZ_6lsWsJRGeaHg/w400-h300/IMG_6052.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">All ready to go<br /></span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Preparation</b></span></div><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-family: arial;">In
my case, and having had so much trouble with that top nut, I wanted
some options here. Before re-assembly I drilled and tapped a small hole
in the top edge of the body - in line with where the nut would be. I planned to fit grub screws. The hole needs to be up near the edge of the casting - with a risk it cracks. The hole and screw size need to be big enough to provide some 'bite', but not so big that the hole gets too close to the edge of the casting. <br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbSyhDXBTq3JJOjF5p-W02QkGJr4ck3SwXvaIvW5DmD8-Uby49waWJUUuPrnpJGoKb93pWz1IUEvZ6Kz1bG5Y2Vg0Ewnhv_Sj3G7fck5no_E2pZKa5gs-2o3fZKBxpjiSwjWd7s5K0Q3k1li6wSlS8zEE9s-0WXMxYBoY7nrK3KqOT7onALD_zhg/s4032/IMG_6055.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbSyhDXBTq3JJOjF5p-W02QkGJr4ck3SwXvaIvW5DmD8-Uby49waWJUUuPrnpJGoKb93pWz1IUEvZ6Kz1bG5Y2Vg0Ewnhv_Sj3G7fck5no_E2pZKa5gs-2o3fZKBxpjiSwjWd7s5K0Q3k1li6wSlS8zEE9s-0WXMxYBoY7nrK3KqOT7onALD_zhg/w400-h300/IMG_6055.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">I added a hole to fit a grub screw</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCp8hE6XIMEk1YqQ8qZdPu9uln0xKoEPXgFlVAiswkZX84mUwA0HGE6viom_RXh57apmUNxb4-42jBeDWwK1pUoxco01DtYn04P2jmW9uvSADDvJKwNp0BY7EdT8xWwWW2p6xnWbxrE6Wzcr0jBwR45WJiQOzXJgNcf-29Jz5zFA5cev_HPYtX7Q/s4032/IMG_6056.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCp8hE6XIMEk1YqQ8qZdPu9uln0xKoEPXgFlVAiswkZX84mUwA0HGE6viom_RXh57apmUNxb4-42jBeDWwK1pUoxco01DtYn04P2jmW9uvSADDvJKwNp0BY7EdT8xWwWW2p6xnWbxrE6Wzcr0jBwR45WJiQOzXJgNcf-29Jz5zFA5cev_HPYtX7Q/w400-h300/IMG_6056.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Tapping the hole for the grub screw<br /></span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><br /></td></tr><tr><td class="tr-caption" style="text-align: center;"><div style="text-align: left;"><span style="font-family: arial; text-align: justify;">With the bearing cups in mind, b</span><span style="font-family: arial; text-align: justify;">efore
you can fully reassemble the arm, it's advisable to make a simple tool
to help with the bottom cup....This is shown in Operation Dx. 433-3. </span></div></td></tr></tbody></table></span></div></div><div style="text-align: justify;"><span><div><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3cpHI0by8twbxJs0B9WmD1rz2T2_GqqRiF163Pt8zD91nlr9rFdEL1wiWNyqsMTVd1TVuBQYNPS5WI1KpEujZCQb_lPVjNcnVbJQn6Wj29v2TeInA9DrHXaYa4SqfynXT9BeaXXwYYjWkroekLW4FlJjCTkEdSm2vst8BNdlSerSYkbkPinJ3Gg/s817/tool.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="540" data-original-width="817" height="265" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3cpHI0by8twbxJs0B9WmD1rz2T2_GqqRiF163Pt8zD91nlr9rFdEL1wiWNyqsMTVd1TVuBQYNPS5WI1KpEujZCQb_lPVjNcnVbJQn6Wj29v2TeInA9DrHXaYa4SqfynXT9BeaXXwYYjWkroekLW4FlJjCTkEdSm2vst8BNdlSerSYkbkPinJ3Gg/w400-h265/tool.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Tool 3904-T</span></td></tr></tbody></table></div><div style="font-family: -webkit-standard; text-align: justify;"><br /></div><div style="font-family: -webkit-standard; text-align: justify;"><span style="font-family: arial;">This
tool is used to push home the arm assembly - and most importantly the
bottom bearing cup. I couldn't find any metal tube of quite
the right dimension. It needs to sit just inside the inner diameter of
the bodyso that it can press down on the face of the bearing cup. In the
end I found a tatty piece of domestic plumbing waste pie that was about
the right size. </span><span style="font-family: arial;"><span style="font-family: arial;">The cut out section slips over the cranked section of the arm.</span></span></div><div style="font-family: -webkit-standard;"><span style="font-family: arial;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAsqKMzFiX1qLovSwGfS-ymhWJoftlL9bq2T1NHVvacsU22Z6Hsu8-xEiFdpAwbqU0OXTypTn9zx7yibuLdUv-W6YdU1w67udCy4c3hw8x2C59HIkHpVwWeDUjLCjZewL_2oy5xl0QPu6Jcqq0RictYC-65an6trZ5X2ZzbESyRMY3aNziz0S69g/s4032/IMG_6066.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAsqKMzFiX1qLovSwGfS-ymhWJoftlL9bq2T1NHVvacsU22Z6Hsu8-xEiFdpAwbqU0OXTypTn9zx7yibuLdUv-W6YdU1w67udCy4c3hw8x2C59HIkHpVwWeDUjLCjZewL_2oy5xl0QPu6Jcqq0RictYC-65an6trZ5X2ZzbESyRMY3aNziz0S69g/w400-h300/IMG_6066.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">My home made tool.</span></td></tr></tbody></table></span></div><div style="font-family: -webkit-standard; text-align: justify;"><span style="font-family: arial;"> </span></div></span></div><div style="text-align: justify;"><span style="font-family: arial;">I applied a little grease to the inside face of the body to help with the refitting of parts. The bearing cups will be a very 'snug' fit. Before I began in earnest, I did a trial fit of the two metal bearing cups in the body - to make sure that when it came to the crunch, they were going to fit nicely. </span><span style="font-family: arial;">This was especially important for me as I had bought replacement cups. </span><span style="font-family: arial;">You don't want to end up forcing and jamming them.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">With the holes tapped and a tool made, and with the fit of the cups tested, I was all set to go.</span></div><div style="text-align: justify;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTfrTh7tgQ8nDDyj9tcqf6jxcbMbACFjqnhIwSvUO6kLU6rXAjwZAymxcNA-tKso31AYv9F3xdBBNjweyinr2ZWyF1cO6vfQ2-UlZkd2kTmKt1jtj5Y23_xsg6rmfcy5YEj2GKb6VTh_1EamThO2qDCr2gYKpLRFjPYQXqd2DdfhHB_CY4LdsGiw/s4032/IMG_6065.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTfrTh7tgQ8nDDyj9tcqf6jxcbMbACFjqnhIwSvUO6kLU6rXAjwZAymxcNA-tKso31AYv9F3xdBBNjweyinr2ZWyF1cO6vfQ2-UlZkd2kTmKt1jtj5Y23_xsg6rmfcy5YEj2GKb6VTh_1EamThO2qDCr2gYKpLRFjPYQXqd2DdfhHB_CY4LdsGiw/w400-h300/IMG_6065.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><div style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Relay arm parts</span></div><div style="text-align: justify;"><br /></div></td></tr></tbody></table><span style="font-family: arial;"><div style="text-align: justify;">There was just one last thing. I familiarised myself with the job ahead and how all the parts should fit together. The scanned pdf diagrams available are quite blurry and don't show you what is inside very well. Here is a better quality scan of the relay arm parts. </div><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYxb8S6I6CcpyefGyEy424m44hnzWHmwclXgBpXb3UgH1feKZG5fWqwCMAFyZqnxxXTIA82JB9ejOt_ocsSY6gGzkPjI9LA4CwEkNPybgA6ux7ndT5tgtPvm9AKCLsX6oStMiWVcYFFGAjUxx_wPXR1jtfTLgBeb5FEm32riSqC5ElcTgc8G_c-Q/s2130/relay.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2130" data-original-width="2125" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYxb8S6I6CcpyefGyEy424m44hnzWHmwclXgBpXb3UgH1feKZG5fWqwCMAFyZqnxxXTIA82JB9ejOt_ocsSY6gGzkPjI9LA4CwEkNPybgA6ux7ndT5tgtPvm9AKCLsX6oStMiWVcYFFGAjUxx_wPXR1jtfTLgBeb5FEm32riSqC5ElcTgc8G_c-Q/w638-h640/relay.jpeg" width="638" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Relay arm parts and their orientation</span></td></tr></tbody></table><div style="text-align: justify;"><br /></div><div style="text-align: justify;">In particular, it's worth noting the angles of the lips on the two seals (parts 5 and 8) and the orientation of the dished washer (part 2)</div></span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;"><div style="font-family: -webkit-standard; text-align: justify;"><span style="font-family: arial;"><b>Top Bearing and Seal</b></span></div><div style="font-family: -webkit-standard; text-align: justify;"><span style="font-family: arial;">The first step of reassembly was to fit the top oil seal in the body. This was pushed down to about the bottom of the machined area - about five or is inches down. </span><span style="font-family: arial;">Push it any further and it will simply fall inside the cast body. </span><span style="font-family: arial;">Look carefully at the lip as it's important to get the seal the right way round. The lip needs to to face up - towards the top of the relay.</span></div><div style="font-family: -webkit-standard;"><span style="font-family: arial;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwT7MAhSXecxZy_Dwa56tGOLEz5FyLYWrSDOkFB11Zj5rt_C5Wz6ZzicslVuj4-nXTgBSnebV3xVVJYlu30TEmkdiT1Nnp7rFkVnIh4I3fHKI180PyGj59ltf5vXgheHg6j1Eqs2UepSs3eruyDuoHFAP3YPQkSaw1CZexYlnWdoMdWBRtpz8QAw/s4032/IMG_6067.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwT7MAhSXecxZy_Dwa56tGOLEz5FyLYWrSDOkFB11Zj5rt_C5Wz6ZzicslVuj4-nXTgBSnebV3xVVJYlu30TEmkdiT1Nnp7rFkVnIh4I3fHKI180PyGj59ltf5vXgheHg6j1Eqs2UepSs3eruyDuoHFAP3YPQkSaw1CZexYlnWdoMdWBRtpz8QAw/w400-h300/IMG_6067.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">New top oil seal in the relay body. Note the angle of the lip</span></td></tr></tbody></table></span></div></span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Next the top bearing cup and it's balls were fitted. The top and bottom bearing cups look similar, but the top cup is the one with the smaller diameter inner hole. Two points. Firstly, you need to h</span><span style="font-family: arial;">old all the 14 balls in place on the cup with a generous amount of bearing grease for fitting.</span><span style="font-family: arial;"> <br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixYRscIUBDTiYyhgM-5Gc-iwd7nLUjzZw3j0HeIKjKp8dNBv3J4qQBCMLca4X-Uhqob2EFAfv4tj6WdndGlKySiUL0_diXxAFPW06_JXCqX7KE5n1awgWQzTy1Gtj_-7V8L6n_CNyII_Xu2sT2iCY3gIGDMl_UlY5AMyyqBXljLeZR6r6AYAckQQ/s546/Top%20cup%20and%20balls.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="394" data-original-width="546" height="289" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixYRscIUBDTiYyhgM-5Gc-iwd7nLUjzZw3j0HeIKjKp8dNBv3J4qQBCMLca4X-Uhqob2EFAfv4tj6WdndGlKySiUL0_diXxAFPW06_JXCqX7KE5n1awgWQzTy1Gtj_-7V8L6n_CNyII_Xu2sT2iCY3gIGDMl_UlY5AMyyqBXljLeZR6r6AYAckQQ/w400-h289/Top%20cup%20and%20balls.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Top bearing cup - ready to fit</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Secondly, invert the body and fit the cup that way - it stops any balls falling into the body. </span><span style="font-family: arial;">Press the cup and ball assembly down (up) into the body until its resting against the oil seal. </span></div><div style="text-align: justify;"><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><span style="font-family: arial;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwH6G7DOWwWZRpO98lbe4-AXYwvwyasVDaniuH8SxENe1rUXFUq2VtcFInlxh_38NGLyayU4BSfXJGSZxGF864rt5_AMeJK6wqD7de_kHvMNs9tiwLYdQCkQD95LoI-x9UM2ZukEbOV-FfTPDExMq6Fy1McEj7DAaJ74AB_fTg_CEthrC4DnJz2w/s4032/IMG_6069.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwH6G7DOWwWZRpO98lbe4-AXYwvwyasVDaniuH8SxENe1rUXFUq2VtcFInlxh_38NGLyayU4BSfXJGSZxGF864rt5_AMeJK6wqD7de_kHvMNs9tiwLYdQCkQD95LoI-x9UM2ZukEbOV-FfTPDExMq6Fy1McEj7DAaJ74AB_fTg_CEthrC4DnJz2w/w400-h300/IMG_6069.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Oil seal, balls, and bearing cup</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">On top of the bearing cup, I placed the flexible (di</span><span style="font-family: arial;">shed) washer. This needs to be fitted so that it's narrower end faces DOWN. If you fit it the other way up, it simply presses against the felt dust seal of the top nut and doesn't do it's job properly.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">Next, the top nut was fitted. This should be fitted so that it's face is just below the top edge of the body (about 1mm or 2mm). If your oil seal was not pressed in far enough before, so the stack of seal, bearings and nut is above the rim - don't worry. The seal will yield under the nut and move down to the appropriate level. If you pressed the oil seal in too far, again - don't worry. Just fit the nut to below the edge of the body. Then, from the other end, gently push the seal back so that it contacts the balls. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">The next job was to set up the relay arm for fitting. I polished up the bearing surfaces to try to compensate for some of the wear.</span></div><div style="text-align: justify;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicQVjk4JEEPsW7Nppk2FS8A5_dHnw9aLIpCD_Y6cNXYVSCHfgXAxvEcWOJQig89bahVJaEiXdZOZCgLO2YiiPF45KPe8NEa3sr4goKaL-87pq_1K4Fpt3D3WcFmRJU6SDd9K5_mAGeMA9yoedjtHbAuCuoAV-Wwz5zRB3K8AvIrqHkQDgu1oHjiQ/s4032/IMG_6078.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicQVjk4JEEPsW7Nppk2FS8A5_dHnw9aLIpCD_Y6cNXYVSCHfgXAxvEcWOJQig89bahVJaEiXdZOZCgLO2YiiPF45KPe8NEa3sr4goKaL-87pq_1K4Fpt3D3WcFmRJU6SDd9K5_mAGeMA9yoedjtHbAuCuoAV-Wwz5zRB3K8AvIrqHkQDgu1oHjiQ/w400-h300/IMG_6078.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">I polished the bearing surface on a wheel</span><br /></td></tr></tbody></table><span style="font-family: arial;"><div style="text-align: justify;"><br /></div></span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Relay Arm Assembly</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">The diameter of the ball joint eye is greater than the dimension of the arm shaft, so these parts cannot be fitted after assembly. I first slipped the metal sealing cap over the shaft. Make sure you get it the right way round. Next was the bottom oil seal. Again - make sure it's the right way round: the lip of the bearing needs to be facing towards the splined end of the relay arm. Next I fitted the lower bearing cup. The dished face, that carries the balls, need to face towards the splined end of the arm. The metal cup and oil seal were slid out of the way towards the ball joint eye. I positioned the bearing cup at it's approximate position with the corresponding groove in the relay arm</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">On the relay body, and with the relay body upside down, check that the balls of the top joint (the ones fitted first) are still in place. </span><span style="font-family: arial;">Some of the balls may have fallen inwards - blocking the hole in the seal - </span><span style="font-family: arial;">but they can be gently coaxed back into position </span><span style="font-family: arial;">with a screwdriver blade or similar.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Now take the arm assembly and generously coat the ball groove, and thinner part of the shaft at the splined end, </span><span style="font-family: arial;">with grease</span><span style="font-family: arial;">. Do the next step over a bench or similar so that you can check no balls get pushed out during assembly.</span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">Hold the cup on the arm over the balls in the groove to stop them falling out. Gently, and gradually, push the splined end of the arm down through the body. Do not go too far or the bearing cup on the arm will simply get pushed back out - with the risk the balls fall out. Carefully locate the bearing cup in the body.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiB-OzhO5NsqQ5AeVctxtduqQp_JoGo3eKa8hJcKVaXmfWZMDV9HhTmRqfFsgy7Z4KCnWoyDSwVCe3ARnc39Vih5r2JlYoZlO3FP5NP5zPhtqFq0NiVsK9yrtSKwRv1oAEg1G_5NWabRLH29NAq6LefiCVRBePjGXyEq97Azk3HikApkFA-39AoCQ/s4032/IMG_6082.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiB-OzhO5NsqQ5AeVctxtduqQp_JoGo3eKa8hJcKVaXmfWZMDV9HhTmRqfFsgy7Z4KCnWoyDSwVCe3ARnc39Vih5r2JlYoZlO3FP5NP5zPhtqFq0NiVsK9yrtSKwRv1oAEg1G_5NWabRLH29NAq6LefiCVRBePjGXyEq97Azk3HikApkFA-39AoCQ/w400-h300/IMG_6082.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Fitting the bottom bearing cup</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">So,
as the splined end starts to emerge from the other end of the body, pay attention to the
cup and balls on the relay arm. This is where you need to make sure the
bearing cup fits straight into the body and does not get snagged. You
want the arm to go through the body only at the pace that allows you to
keep the cup on the arm, in contact with the balls on the arm. They both
need to go back in together and this is where that tool gets used.</span><span style="font-family: arial;"> <br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">Placing the tool over the cranked arm, gently tap down on the tool, so that it presses on the cup. </span><span style="font-family: arial;">The cup will press against the bearings in the arm and gradually push the who lot through the body.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzUTCWUQa2IepsTMnUyYu87gt-tBapOkUDhOJzMjv-3xRaI1zhQhv0ZdPu03vxg22YYEGHH-HXl0LyE_lAV1p8-p7aF9ntoRz4r283rWj8w30St1s0ZUe8gmUyzfk6QksFZoeNxCFFcjzEf_QHzaCQhAGAVbppWW8zDFyWkRra6CzCS2fM0P3o5g/s4032/IMG_6074.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzUTCWUQa2IepsTMnUyYu87gt-tBapOkUDhOJzMjv-3xRaI1zhQhv0ZdPu03vxg22YYEGHH-HXl0LyE_lAV1p8-p7aF9ntoRz4r283rWj8w30St1s0ZUe8gmUyzfk6QksFZoeNxCFFcjzEf_QHzaCQhAGAVbppWW8zDFyWkRra6CzCS2fM0P3o5g/w400-h300/IMG_6074.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Home made tool for fitting the bottom bearing</span><br /></td></tr></tbody></table><div style="text-align: justify;"> </div></span></div><div style="text-align: justify;"><span style="font-family: arial;">To make sure you are applying pressure evenly on the bearing cup, you can carefully rotate the arm a little and then tap again. In fact it helps to rotate the arm anyway, just to make sure nothing is binding anywhere.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Eventually you will find that the arm is pushed fully home (i.e. the dished shoulder of the arm is pressed against the top bearings - which are held in place by the top cup and top nut). How will you know? Well, if the assembly has gone in as it should, you will be able to see and groove for the circlip at the cranked end of the arm. </span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;">And the next step is to fit that circlip. I managed to snap one and promptly stick it through my finger. Now I know what having your ears pierced feels like.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiL6wpG_YG-FYU7gE7uJv1QyWuN7ush_aaNZsl9wT_nTeXhAkX-JUkf85s4Hq8UgLSKxt522O9WrMMOXSu_RnAQCl3FdVkK7KJrCSigUg2jg4xcW_mQ-jRdgB2-LwZoxGBFtGCXZ2P7i3dwbsta3ajSCI3jciWUqD8BJGHCsAue-M_FMo-gWPKHSA/s4032/IMG_6041.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiL6wpG_YG-FYU7gE7uJv1QyWuN7ush_aaNZsl9wT_nTeXhAkX-JUkf85s4Hq8UgLSKxt522O9WrMMOXSu_RnAQCl3FdVkK7KJrCSigUg2jg4xcW_mQ-jRdgB2-LwZoxGBFtGCXZ2P7i3dwbsta3ajSCI3jciWUqD8BJGHCsAue-M_FMo-gWPKHSA/w400-h300/IMG_6041.JPG" width="400" /></a></div><div style="text-align: justify;"><br /></div></span></div><div style="text-align: justify;"><span style="font-family: arial;">Luckily they are a standard size and it was easy to replace. (The circlip - not the finger). If you find that not quite enough groove is exposed to fit the circlip, try backing the top nut off very slightly and then tapping the arm home again from the cranked end. With the circlip fitted, the oil seal can be pushed home and the metal sealing cap fitted.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">It probably took more time for me to type the above, than it did to actually do the job. It just needed a bit of thought and preparation beforehand.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">There is a particular torque for the top nut - but it's difficult to achieve without some kind of a nut tool that accepts a torque wrench. It's not very technical anyway: The nut is tightened to 6m.kg. I think this pushes everything together and removes any slack). The nut is then backed off until it is only just touching the dished washer. Finally the nut is re-tightened a third of a turn. this is expected to correspond to 2m.kg. However this assumes you are using a new dished washer and a new top nut.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">Once you are happy, peen the edge of the nut over into the groove of the body. Or tighten your grub screw if you do as I did.</span></div><div style="text-align: justify;"><span style="font-family: arial;"></span><div style="text-align: justify;"><span style="font-family: arial;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUjBi3FyzXScsufRKOMU5XMP36ZqrWkbyH2SshqNXfFysSveKsxMqF2sInvODoOetKuMABkTUH_wIvSIsQpMmvI3kr1yz6SM-ARehL69BzkrpReqxpyQjPU5zr1Lf4-nLeDdRPf0LI__fJQ_o8eiCCFspsoifSPTTMdiYVn8MpxG6UwKXug-oIGg/s4032/IMG_6058.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUjBi3FyzXScsufRKOMU5XMP36ZqrWkbyH2SshqNXfFysSveKsxMqF2sInvODoOetKuMABkTUH_wIvSIsQpMmvI3kr1yz6SM-ARehL69BzkrpReqxpyQjPU5zr1Lf4-nLeDdRPf0LI__fJQ_o8eiCCFspsoifSPTTMdiYVn8MpxG6UwKXug-oIGg/w300-h400/IMG_6058.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Grub screw in place</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><br /></div></div><div style="text-align: justify;"><span style="font-family: arial;">From what I can gather, the arm should be held 'securely' in the body: with the relay unit held on it side, the cranked end of the arm should not fall under gravity if the unit is shaken slightly - yet should move smoothly (more smoothly than it did perhaps?) when you push it with your finger. You might need to tighten or slacken the top nut slightly until you are happy with the pressure. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">My uncertainty over this is one of the reasons I chose to try using grub screws to secure the nut. </span><span style="font-family: arial;">A grub screw is probably not as secure as peening the nut edge over - but neither is it as destructive and I think that, if I needed to, the relay unit nut could be removed or re-adjusted again.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Alternatives</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">There are several alternatives to your own rebuild. </span><span style="font-family: arial;">If you're worried about your skills, or the quality and longevity, you can go for an upgrade. The arm is machined and re-profiled to take (three?) modern, sealed roller bearings. These kits can be bought for about £80 each - so temptingly cheap really. </span></div><div style="text-align: justify;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaLaR_QwKRGeZiSUX5oZjtdE6g9YlX9ZNBIslAsxQGYQPp0IEDfR2AP1ulAH3w8wxvVsmQdb6i6Aea17vrV-SCfSYRELolFzUWyFCGG06Oq_X9DGO_neEFVHqjth7iR114XlWucXXXy3ILnuyT-UpBZGCY113lhgyUICqr8lULRmlT1dQR-KIkZA/s1225/arm%20kit.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="259" data-original-width="1225" height="136" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaLaR_QwKRGeZiSUX5oZjtdE6g9YlX9ZNBIslAsxQGYQPp0IEDfR2AP1ulAH3w8wxvVsmQdb6i6Aea17vrV-SCfSYRELolFzUWyFCGG06Oq_X9DGO_neEFVHqjth7iR114XlWucXXXy3ILnuyT-UpBZGCY113lhgyUICqr8lULRmlT1dQR-KIkZA/w640-h136/arm%20kit.jpeg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Upgraded relay arm kit. Note re-profiling. (photo credit: Der Franzose)</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">However there is another hurdle to be overcome before these can be used. As originally produced, t</span><span style="font-family: arial;">he relay bodies are machined internally to accept bearing cups with a diameter of 46mm. It's the same for the oil seals. The new modern bearings have an outer diameter of 47mm. So before these arms can be used, you need to get the bodies machined to 47mm to suit. </span><span style="font-family: arial;">There was an error on Franzoses website and when I originally ordered replacement 46mm seals for my arms, 47mm seals turned up. Franzose gave me a no-quibble replacement, so I can't complain. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">This cheaper route also relies on you being able to re-use your top nut and not buggering up the threads. </span><span style="font-family: arial;">Having already tried the rebuild route that I followed, Peter eventually went down the path of re-profiled arms and new seals. he was lucky enough to find new top nuts. That's why he was able to offload various bits on me. He knows his way around a lathe but had to seek out someone else to machine his bodies for him.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">If all of this sounds like too much hassle, it looks as though you can buy these upgraded arms with all the work done for about £200 each. </span><span style="font-family: arial;">You need to send back your old arms to have them overhauled for the next customer.</span></div><div style="text-align: justify;"><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: justify;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2mSb_N6O3JmTtA93SxmkIDmpOnHOqzc_mmPjweiLJ_kpTVoRltK9C6iUAofhIGiq-tab-JrCdMYKzfhRHV5546YxewjI1QLzV7NrjfQvZtlRShH0JIYv95Zn0q4rAPPJy7wFJrIzGCzw_nK5R-1Gk5YahDyhdNn4cAGiacV68xK6R007rFIevxA/s1048/Citrotech.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="677" data-original-width="1048" height="259" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2mSb_N6O3JmTtA93SxmkIDmpOnHOqzc_mmPjweiLJ_kpTVoRltK9C6iUAofhIGiq-tab-JrCdMYKzfhRHV5546YxewjI1QLzV7NrjfQvZtlRShH0JIYv95Zn0q4rAPPJy7wFJrIzGCzw_nK5R-1Gk5YahDyhdNn4cAGiacV68xK6R007rFIevxA/w400-h259/Citrotech.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: justify;"><div style="text-align: center;"><span style="font-family: arial; font-size: small;">A re-profiled, and rebuilt arm (photo credit: Citrotech)</span></div><span style="font-family: arial; font-size: x-small;"><div style="text-align: center;"><br /></div></span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I probably spent about £70 in total rebuilding my arms. But there was effort, anxiety (and blood) along the way. What I've ended up with is better than what I had before, but almost certainly not as good as these rebuilt units. However it has left me free to waste my money on other things-DS.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">My two arms have distinct casting marks and I will make sure I put them back on the sides they came from. I'll also make sure I put back all the relevant packing washers.</span></div><div style="text-align: left;"><br /></div></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-85817517245080566402022-11-20T16:24:00.002+00:002023-03-03T14:40:25.075+00:00Servicing The Heater Valve<div style="text-align: justify;"> <span style="font-family: arial;">A nice, simple, one this.....</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjo242hp77KMDPdV6mGvom7toTnk_GFDRZ1mZCvC-1xNXYdu73qoTcvsXlQD7ro4ksTTNbv_Ma_JQ_3uDCkX9_XM6XtlzQzT8knwP1zdYjxtTNpDfSgGFn8XOfU8QNr6DqUiWYP8QPyA-amnzwCbtkKSVtoPN-i6GYyb67NEZMQC6VySlCzVMlYJA/s4032/IMG_5822.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjo242hp77KMDPdV6mGvom7toTnk_GFDRZ1mZCvC-1xNXYdu73qoTcvsXlQD7ro4ksTTNbv_Ma_JQ_3uDCkX9_XM6XtlzQzT8knwP1zdYjxtTNpDfSgGFn8XOfU8QNr6DqUiWYP8QPyA-amnzwCbtkKSVtoPN-i6GYyb67NEZMQC6VySlCzVMlYJA/w400-h300/IMG_5822.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Heater valve on a mid/ late 1960s car</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">From the 1969 model year (so about September 1968), the valve to control the heater was mounted on top of the heater matrix and controlled by a lever and cable. Prior to that, the valve was mounted on the bulkhead below the dashboard and operated by a rotating knob. </span><span style="font-family: arial;">My car, being a 1968 model year car was one of the last to have the rotating knob.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis755YGIEt9xN3Mz5dUOVCTwewAym3YE3guJwQzEsnGHmgjpSgMtZ6Mdld9fYfWgw_xF4byBP9MB7m_cWi1yX7iLk_v7UuZdJ1y0zBO4qS2KYiWJUvvwnT1ZeGMNUPHLD7UX_mvsvUP0FF0rU6CmCvz86Lz-PIUjyvHXEiVU4QggUnFrE0kOshQg/s2641/IMG_6384%20copy.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1796" data-original-width="2641" height="272" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis755YGIEt9xN3Mz5dUOVCTwewAym3YE3guJwQzEsnGHmgjpSgMtZ6Mdld9fYfWgw_xF4byBP9MB7m_cWi1yX7iLk_v7UuZdJ1y0zBO4qS2KYiWJUvvwnT1ZeGMNUPHLD7UX_mvsvUP0FF0rU6CmCvz86Lz-PIUjyvHXEiVU4QggUnFrE0kOshQg/w400-h272/IMG_6384%20copy.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Pallas-trim on the heater knob</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The styling around the knob, and of the knob itself, varied between ID/ DS and pallas spec models, but the function and valve are the same.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgErXB4rjn5Upky6ufu4xqhRtbYub3X8lnNZJatNaTmhX_Tw0LpOx_J6tszixpKpPNBXKMvW5APy7WAgGBYxh25KBY7ii_xCnIyTJbfxJVV1fnkhZFBNwrLAROGIyAz6JqoujqyNqJCgEyKzFCsxyO_Hd-hjdxGuiDU3Ls6faw2AwTukhPzMrKMvw/s1373/Mark%20Rueneuf.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="972" data-original-width="1373" height="284" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgErXB4rjn5Upky6ufu4xqhRtbYub3X8lnNZJatNaTmhX_Tw0LpOx_J6tszixpKpPNBXKMvW5APy7WAgGBYxh25KBY7ii_xCnIyTJbfxJVV1fnkhZFBNwrLAROGIyAz6JqoujqyNqJCgEyKzFCsxyO_Hd-hjdxGuiDU3Ls6faw2AwTukhPzMrKMvw/w400-h284/Mark%20Rueneuf.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">DS/ ID variant of the heater knob<br />(photo copyright Mark Rueneuf) </span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">As well as looking retro and cool - especially as they were married to the 60s DS and ID 'gris rose' dashboards........</span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEin6lOyS8WNKObT16T6cMR2eFRvP_H4FjMIWAFHPpjcUq5XWALGNGL7Pj-l56ulACZ-wkalxSwum5hA9cYH_LW__IEJZ0aW05wqcvh--cc5UsRR8WGzOCZD0M6edG5Qn6CNqvuU67nXZceyQS0kvZhqlRcHXpZzWqvNoR69AuPCEczQkl2bVGf3HA/s1108/dash.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="594" data-original-width="1108" height="344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEin6lOyS8WNKObT16T6cMR2eFRvP_H4FjMIWAFHPpjcUq5XWALGNGL7Pj-l56ulACZ-wkalxSwum5hA9cYH_LW__IEJZ0aW05wqcvh--cc5UsRR8WGzOCZD0M6edG5Qn6CNqvuU67nXZceyQS0kvZhqlRcHXpZzWqvNoR69AuPCEczQkl2bVGf3HA/w640-h344/dash.jpeg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Heater knob in a 1968 DS<br />(photo copyright French Classics)</span></td></tr></tbody></table><div style="text-align: justify;"><span style="font-family: arial;">........the valves are a lot simpler. </span><span style="font-family: arial;">The later plastic valves tended to clog up easily and the bases would crack and they would leak. The bulkhead mounted valves were made from brass, had fewer moving parts, and were sturdier. </span><span style="font-family: arial;">Unfortunately they still clogged up and the valves jammed.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">If yours is jammed, think very carefully before you apply brute force as the ends can, and do, snap off. The weak spot is the threaded part at the end.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyO6wOzfxLqCwroSktIlAgk5WN0fqS--EJl3Lm36fG-CUyNhmq97jx9GBwWUpqIZgDOu0Uc0W8cmO9jPqETBTOKLJlsBDjg6604MTXNOxAbw8s_evCPF_OSXs-vQchamZ2uhcUOhiJzuErWjVPuBmV_3vVi9-jJjdN5rtFOF-LszsQsj7xD_Crww/s1920/Jonathan%20palmer.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1440" data-original-width="1920" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyO6wOzfxLqCwroSktIlAgk5WN0fqS--EJl3Lm36fG-CUyNhmq97jx9GBwWUpqIZgDOu0Uc0W8cmO9jPqETBTOKLJlsBDjg6604MTXNOxAbw8s_evCPF_OSXs-vQchamZ2uhcUOhiJzuErWjVPuBmV_3vVi9-jJjdN5rtFOF-LszsQsj7xD_Crww/w400-h300/Jonathan%20palmer.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Broken spindle....<br />(photo copyright Jonathan Palmer)</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">If you need to service your valve, the other downside of these ones is that they are far less accessible than the ones on top of the heaters. They are tucked down at the back of the engine.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPagyShOqXFnwD-V18saRAkYqBPjt8dOo-x6ELYj8WFBacNbZxDjPo6THMmR44zocWNXYmpZfosaKZ6IN3AKp3XpEy0s8Wb811MGjdrepJeqVq34yGVwosdbFJEJnFEebt8zGUDGG_DloKh8Cu7QXrgDYUqmI3UA9vn_hsajr_aE5aiaNMUvYqDg/s2437/Heater%20hose%20from%20valve%20to%20matrix%20copy.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1690" data-original-width="2437" height="278" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPagyShOqXFnwD-V18saRAkYqBPjt8dOo-x6ELYj8WFBacNbZxDjPo6THMmR44zocWNXYmpZfosaKZ6IN3AKp3XpEy0s8Wb811MGjdrepJeqVq34yGVwosdbFJEJnFEebt8zGUDGG_DloKh8Cu7QXrgDYUqmI3UA9vn_hsajr_aE5aiaNMUvYqDg/w400-h278/Heater%20hose%20from%20valve%20to%20matrix%20copy.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The valve is down the back behind the engine</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I'm reliably informed that you can remove the valve with the engine in situ. The first step to removal is to free-up the valve on the engine bay side. </span><span style="font-family: arial;">There is very little working room between the engine and bulkhead. </span><span style="font-family: arial;">Even less if your car has the extra aluminium heat shields. As such, it</span><span style="font-family: arial;"> is virtually impossible to access and loosen hose clips - even more so if they are the original 'Mirex' buckle clips. </span></div><div style="text-align: justify;"><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVjr1PrWTFogzQickIN6CluflKbSht4kvO3B39XZ4hVKmzhu3UmYO7o_6Xd-WFsDnDsvrl_RwjpoeV-85AmmT3QTDfuWhxtm5HT3wAKUeg-_GTj8DFVeLJV4FaiXZK9tmcdNDZRf97P6Ghqzis6FHJt4n5L0SiblwqOybMGZIlSfYKj57r3sNIxw/s3264/IMG_2652.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVjr1PrWTFogzQickIN6CluflKbSht4kvO3B39XZ4hVKmzhu3UmYO7o_6Xd-WFsDnDsvrl_RwjpoeV-85AmmT3QTDfuWhxtm5HT3wAKUeg-_GTj8DFVeLJV4FaiXZK9tmcdNDZRf97P6Ghqzis6FHJt4n5L0SiblwqOybMGZIlSfYKj57r3sNIxw/w400-h300/IMG_2652.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Hose clips on the valve body. Note that my hoses had been leaking!</span></td></tr></tbody></table></div><div><span style="font-family: arial;">You might be tempted to cut the hose ends. This is fine: one of the hoses is a specific moulded 'S' shape, but both hoses are available as modern reproduction parts. The quality of the rubber may not be as good - but they will work.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqHeckGt5pMu6FilM-jTHHScO_7eRMM1xc7xgBgd9eVivKFD1TXhEiQfF-l_YiEWWHEjNLvHWv5DYYhQyNgNZOpDUTEviZjgPZePS-wnKP81j4vR3AaRUYJIqfQzfB52ZYzQxlsemf3bPeelxZRmvaLiCjKBq_pAdolNDp1TlmAXBk_sdm30j5aw/s4032/IMG_5840.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqHeckGt5pMu6FilM-jTHHScO_7eRMM1xc7xgBgd9eVivKFD1TXhEiQfF-l_YiEWWHEjNLvHWv5DYYhQyNgNZOpDUTEviZjgPZePS-wnKP81j4vR3AaRUYJIqfQzfB52ZYzQxlsemf3bPeelxZRmvaLiCjKBq_pAdolNDp1TlmAXBk_sdm30j5aw/w400-h300/IMG_5840.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Original hoses (top) and a reproduction (bottom)</span></td></tr></tbody></table></div><div><span style="font-family: arial;">The best way to loosen the valve on the engine bay side is to tackle the other ends of its two hoses: one</span><span style="font-family: arial;"> on the feed pipe from the cylinder head (behind the air cleaner) and one on the heater matrix itself.</span></div><div><br /></div></div><div style="text-align: justify;"><span style="font-family: arial;">With the hoses undone, the valve itself is removed by first either removing the rubber cover from the knob (if the car is a DS or ID) or by winkling out the stainless steel disc from the knob if the car has Pallas spec. trim.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgoed3APC8gZO61gwfK2xs9luxWGjcjhgp9BjzgZTy6B6Jf-ivsYbmEulc2Xskg5_nX5kGtADUc9ui2tX0QsHRLq3dHOn9sNQ0S0IGnKR8t7A4bArhRDlIV_7s271NVKD_kzcJVuVTWahiISULAQdpns0BXe7PNi6Zg1hYf4_DRSFGCFwAVw7U3UQ/s4032/IMG_5814.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgoed3APC8gZO61gwfK2xs9luxWGjcjhgp9BjzgZTy6B6Jf-ivsYbmEulc2Xskg5_nX5kGtADUc9ui2tX0QsHRLq3dHOn9sNQ0S0IGnKR8t7A4bArhRDlIV_7s271NVKD_kzcJVuVTWahiISULAQdpns0BXe7PNi6Zg1hYf4_DRSFGCFwAVw7U3UQ/w400-h300/IMG_5814.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Stainless steel capping disc on a Pallas knob</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">In both cases this reveals a nut to remove the rest of the knob and temperature indicator.</span></div><div style="text-align: justify;"><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOrFKfBeAKJ17oCd_tA4MguyVY4wqCVq4-3ywSFdXVwRqJReNnqZg6Zh33a0JdfAZerlwY9T3WujTQjtIwfx1R2qbjvyaX6alXY8PJ-oOW5jJlrbY4Jvwzm7RJtB8AtQGxy2818cuwEQ5GZiSAj_9n1txbIRAKblhz6i07hqZTpVPNCOSi_fHFQQ/s4032/IMG_5815.JPG"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOrFKfBeAKJ17oCd_tA4MguyVY4wqCVq4-3ywSFdXVwRqJReNnqZg6Zh33a0JdfAZerlwY9T3WujTQjtIwfx1R2qbjvyaX6alXY8PJ-oOW5jJlrbY4Jvwzm7RJtB8AtQGxy2818cuwEQ5GZiSAj_9n1txbIRAKblhz6i07hqZTpVPNCOSi_fHFQQ/w400-h300/IMG_5815.JPG" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">The valve itself is them removed by undoing the two cheese-headed screws from within the cabin. These two screws also serve as the 'stops' for the rotation of the knob between hot and cold.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJz4xzo9DwhSpAfZgdXYsn9OILCn5hbGaPNdtz98-upOAemBcnsCvz6IIebr6acYavqvwjGJGxfEPqInbOGA6YhPWCLTo1ZAmfbokpmji9dGD3R2U9uddFtvhlFI4hdbt9RtsYtrGAVgGQOD6TejB4aCXDInPWXi4ctLUz51P-8b-vQbtJuhrjqw/s3264/IMG_0785%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJz4xzo9DwhSpAfZgdXYsn9OILCn5hbGaPNdtz98-upOAemBcnsCvz6IIebr6acYavqvwjGJGxfEPqInbOGA6YhPWCLTo1ZAmfbokpmji9dGD3R2U9uddFtvhlFI4hdbt9RtsYtrGAVgGQOD6TejB4aCXDInPWXi4ctLUz51P-8b-vQbtJuhrjqw/w400-h300/IMG_0785%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Screws holding the heater valve in place</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><div style="font-family: -webkit-standard;"><span style="font-family: arial;">The valve spindle is a tight fit through the bulkhead, so needs to be pushed back through all the way before it can be angled and lowered down and out.</span></div><div style="font-family: -webkit-standard;"><span style="font-family: arial;"><br /></span></div><div style="font-family: -webkit-standard;"><div><span style="font-family: arial;">In theory, at least, there is another way. If you wanted to remove the valve from the bulkhead with the engine in situ, removing the rubber/ metal plate would leave a bigger hole in the bulkhead and provide more wiggle room. I removed mine, h</span><span style="font-family: arial;">owever (as the marks on the rubber in the photo show) that rubber plate sticks to the sound deadening on the bulkhead and was surprisingly hard to remove - even with the engine out. It was stuck so fast that at one point I wasn't even sure it COULD be removed.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB-p14WdGHWJBRG_Y_b3jMpKBas76FsNI9r-2SHhZEYf24AoqZs7pgf1d6hX2_MEHxFXQoG7EMei83wFA9RFrDS0_lTyOXMjVQfz9jWdkSu_jrxt9kjwVqoodAW07Ncznf3QqlM_HA6WcZ3Ab5ofR0pOGLq6WoVWYSNgMrRMxx8qaaGPi3M1a39w/s4032/IMG_3708.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB-p14WdGHWJBRG_Y_b3jMpKBas76FsNI9r-2SHhZEYf24AoqZs7pgf1d6hX2_MEHxFXQoG7EMei83wFA9RFrDS0_lTyOXMjVQfz9jWdkSu_jrxt9kjwVqoodAW07Ncznf3QqlM_HA6WcZ3Ab5ofR0pOGLq6WoVWYSNgMrRMxx8qaaGPi3M1a39w/w400-h300/IMG_3708.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Rubber seal and backing plate</span></td></tr></tbody></table></div></div><div style="font-family: -webkit-standard;"><br /></div><div style="font-family: -webkit-standard;"><span style="font-family: arial;">I vaguely recall, many years ago - back in the 1990s - that my valve got stuck and stopped turning. I took the opportunity while the engine was out to remove and free it up. </span><span style="font-family: arial;">I managed to find an 'O' ring that fitted and that was that. </span><span style="font-family: arial;">The car has since stood idle for decades and rubber doesn't last for ever so, given the passage of time, I felt I needed to go back and re-do that job.</span></div><div style="font-family: -webkit-standard;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbtkBrJBg92Mr8rOlo_iiDMmMzDfym7EpJ0-T0Y80N2X-lN-VslRLuXMFF9aIMCdtN7U5faEq7K51N65DDHZ6wKzbEm-fsid0ezdVwaRp6XMrMe1JMVHEDRvEebOupz_sTDQG8_a3E-S0W9TKez__zubIpxBQhnJ_r0op_wX0vwZ3tpsUBSqovaA/s1773/Mick%20Groombridge_Pressure%20wash%20engine%20bay%201.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1773" data-original-width="1167" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbtkBrJBg92Mr8rOlo_iiDMmMzDfym7EpJ0-T0Y80N2X-lN-VslRLuXMFF9aIMCdtN7U5faEq7K51N65DDHZ6wKzbEm-fsid0ezdVwaRp6XMrMe1JMVHEDRvEebOupz_sTDQG8_a3E-S0W9TKez__zubIpxBQhnJ_r0op_wX0vwZ3tpsUBSqovaA/w422-h640/Mick%20Groombridge_Pressure%20wash%20engine%20bay%201.jpg" width="422" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Engine out - circa November 1998</span></td></tr></tbody></table></div></span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">Once I'd committed to removing my car's engine (again) in 2015, I always planned to service the heater valve (again).</span></div><div style="text-align: justify;"><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWe0QyAbnwicae-ufLXdkyOSOjn4SXQZqjhnMnsZOEZlopfKtTuBUByXubR_MVmvEx6P0ejawjiX0VflFzB6seznoHvK6ZlXyOlxPpuMOhiiIQleP4hXC4Q3KwQsp1MXSzK0ZcvQZ6qB3j4ISk25TXjJITwXjtTYRqrLMQyfR0wi8KSwV9jTdjDQ/s3264/IMG_0779.JPG"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWe0QyAbnwicae-ufLXdkyOSOjn4SXQZqjhnMnsZOEZlopfKtTuBUByXubR_MVmvEx6P0ejawjiX0VflFzB6seznoHvK6ZlXyOlxPpuMOhiiIQleP4hXC4Q3KwQsp1MXSzK0ZcvQZ6qB3j4ISk25TXjJITwXjtTYRqrLMQyfR0wi8KSwV9jTdjDQ/w400-h300/IMG_0779.JPG" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">I'd already removed the valve and the rubber/ metal back plate it fits to a year or so ago, as part of plans to repaint the engine bay. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXXYI6wM-jM0WEOR22LWNeV3BdQALdqmKXFzXT0U7HwqMP_GU99nJeAcAeURMyhTI0RIRZd_E2f8jCzLQ1ls90Sf4xkknOmg0snWB0XPCWy090ZUey3ADzqewruDgvE-9klM-TkYhvimNfPYsJWrMtUyDmE4CJo_mceCkunaDD9XIPIVEvjdXS_g/s4032/IMG_3709%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXXYI6wM-jM0WEOR22LWNeV3BdQALdqmKXFzXT0U7HwqMP_GU99nJeAcAeURMyhTI0RIRZd_E2f8jCzLQ1ls90Sf4xkknOmg0snWB0XPCWy090ZUey3ADzqewruDgvE-9klM-TkYhvimNfPYsJWrMtUyDmE4CJo_mceCkunaDD9XIPIVEvjdXS_g/w400-h300/IMG_3709%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Heater valve and backing plate</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The valve was unscrewed from the plate - just as you would do if the plate/ valve assembly was in situ on the bulkhead.</span></div><div style="text-align: justify;"><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpwKVnTaWXr7LPmodN3k-BgO598EpU3gOqeTvgLTRtdUawu0PoOJFnQRQqXnsh6HSDln1lzKm02Kc9zecDdD45LEo0jl_KAYThpFNW6X-R2Fr5zPloDyFL7KcvtpS2aPcvnunUgNkGT4yogRbZKbDiiwcYuU44N5aK-8nr674HZjh3k8QlQHiOfw/s4032/IMG_5776.JPG"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpwKVnTaWXr7LPmodN3k-BgO598EpU3gOqeTvgLTRtdUawu0PoOJFnQRQqXnsh6HSDln1lzKm02Kc9zecDdD45LEo0jl_KAYThpFNW6X-R2Fr5zPloDyFL7KcvtpS2aPcvnunUgNkGT4yogRbZKbDiiwcYuU44N5aK-8nr674HZjh3k8QlQHiOfw/w400-h300/IMG_5776.JPG" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">With the valve removed, the spindle (the part with the threaded end) should just pull out of the body - as it's only the rubber 'O' ring that's holding it in place.</span><span style="font-family: arial;"> In my case, it's an 'O' ring I put in about 25 years ago. </span><span style="font-family: arial;">My spindle shows the battle scars from the mole grips I used to get it rotating back in the 1990s. At least I gripped around the main shaft and managed to avoid snapping the threaded part off. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU4MPvPeCtuzizEgW5Tc-IEJs1k9cTo06eTRYlrzVPRibUaf8dPXXhHCqnbc27rPayU6V3Cf_NgdLt_uRG7ixIaPLDOiloqUHTgm1PEJx--r-dArCLS-m3GZtIsr00MYAc6r5JIVxAkuvf4te_9vG9jN2a8Zrlyi3C6Y55ZP1HL4aQzLCMwNDieg/s4032/IMG_5778.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU4MPvPeCtuzizEgW5Tc-IEJs1k9cTo06eTRYlrzVPRibUaf8dPXXhHCqnbc27rPayU6V3Cf_NgdLt_uRG7ixIaPLDOiloqUHTgm1PEJx--r-dArCLS-m3GZtIsr00MYAc6r5JIVxAkuvf4te_9vG9jN2a8Zrlyi3C6Y55ZP1HL4aQzLCMwNDieg/w400-h300/IMG_5778.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Spindle removed from the valve body</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">It's maybe worth noting at this point, the shape of the valve part of the spindle and in particular the cut out that gives varying levels flow as the knob is rotated. I'm not sure what the thin slot is for? Perhaps to absorb heat expansion? Perhaps to allow a small flow even when the valve is closed?</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj63PJeOUWsAwJJ_gak30aseaRDg-44brB8tWHDHeoKOSh0gUrlREfC8y3Yu99YXFhO9J8bwQ-E-KKMtwVRn_DW1oIk_LYcL0cCa5csAPFOPjkIq-ph9yaAgG_2LVdAXIwHix5-saitRMAemDEIOzHYPK6HNWBBtqUq2nPwl27U_3fKCb6HlAIldQ/s1758/IMG_3712.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1317" data-original-width="1758" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj63PJeOUWsAwJJ_gak30aseaRDg-44brB8tWHDHeoKOSh0gUrlREfC8y3Yu99YXFhO9J8bwQ-E-KKMtwVRn_DW1oIk_LYcL0cCa5csAPFOPjkIq-ph9yaAgG_2LVdAXIwHix5-saitRMAemDEIOzHYPK6HNWBBtqUq2nPwl27U_3fKCb6HlAIldQ/w400-h300/IMG_3712.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Note the thin slot</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Starting with the valve body, I used some emery cloth to gently clean the bore where the valve spindle sits. It's soft brass, so don't use anything too abrasive. I also used a small wire wheel on a Dremel to go up and down the bore to polish it a little.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">With the 'O' ring removed, I lightly cleaned the spindle with wire wool. I used a file to dress the worst of the gnarled edges from the mole grips. I also cleaned up the threads on the screws. Yhese stick through into the bulkhead and their ends tend to rust. I decided to run all the parts though my ultrasonic cleaner. rather than fill the whole thing with cleaner, I just put the parts in a small jar of heated cleaning fluid and filled the rest of the ultrasonic cleaner with hot water.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHghXYI0paCiBjVTGQsrUtu4d4kLPAOhd8ip_M7Y7oaDVWBDrQDhxGYd23wnPpBGYlfl_tHEYjiJWvEZfUTUyspCasOKW3Dcjb_iJCbZUt2ZOfGBe4pAzfCiM7XidcN1RyZJooC8F2Ooz4I49uR2D08Z3HLTDBaxXk_3UyxvC_5l8STLG6wq3amg/s4032/IMG_5780.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHghXYI0paCiBjVTGQsrUtu4d4kLPAOhd8ip_M7Y7oaDVWBDrQDhxGYd23wnPpBGYlfl_tHEYjiJWvEZfUTUyspCasOKW3Dcjb_iJCbZUt2ZOfGBe4pAzfCiM7XidcN1RyZJooC8F2Ooz4I49uR2D08Z3HLTDBaxXk_3UyxvC_5l8STLG6wq3amg/w400-h300/IMG_5780.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Parts to go in the ultrasonic cleaner</span></td></tr></tbody></table><span style="font-family: arial;">The ultrasonic cleaner did a fair job of cleaning the parts up, but they still looked tarnished so, after removal and rinsing I gave them a clean with 'Brasso' - followed by another ultrasonic bath. And then it was time for reassembly.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">There is no point in dismantling and cleaning the valve if you are not going to fit a new 'O' ring. recently John Titus - another Citroen enthusiast - recommended a 'size 112' 'O' ring for this job. He also recommended one made from 'EDPM' rubber, as opposed to 'nitrile' or 'buna'. Nitrile rubber is used in marine (wet) applications but performs less well in hot conditions. The benefit of EDPM is that it more resistant to heat and can stand temperatures over 100 degrees. It's weakness is that it is not very resistant to petrol, oils and solvents. </span><span style="font-family: arial;">That isn't going to be a problem in the valve of a cooling system - provided you use the right lubricating grease. It's best to use silicone grease. Don't be tempted to use Vaseline (aka petroleum jelly). The clue is in the name. Plus it has a low melt temperature so is not suited to a hot water valve. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5AiS1eLb2w4oDzUT7al_IDmg5uQttiU8fT8mRNcSdONauuAlSfrYv9P024fctsXIAliSpaFsTnL7S5Ik6Lo-PGRzRCz4AymT32HY2MBpTsI4B7Xc-gNsUIfaZta2A-qW4RoSc8kFRwINEo1_aQtNe8Twk1tLi2Y6VT9mpKMAUY0ejOMDDuwYRBA/s4032/IMG_5802.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5AiS1eLb2w4oDzUT7al_IDmg5uQttiU8fT8mRNcSdONauuAlSfrYv9P024fctsXIAliSpaFsTnL7S5Ik6Lo-PGRzRCz4AymT32HY2MBpTsI4B7Xc-gNsUIfaZta2A-qW4RoSc8kFRwINEo1_aQtNe8Twk1tLi2Y6VT9mpKMAUY0ejOMDDuwYRBA/w400-h300/IMG_5802.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">All ready for reassembly</span></td></tr></tbody></table><span style="font-family: arial;">I sourced a size 112 EDPM 'O' ring from Ebay. It fitted a treat. I also sourced some silicone grease. This particular one has an effective operating temperature range of -40 to +220 degrees centigrade so should have a long life in service.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I greased the groove where the 'O' ring sits and reapplied a little grease after I had located it. While it's the 'O' ring on the spindle that seals in the bore, I also smeared a thin film of grease on the bore and spindle body to help reduce the risk of jamming. I was careful not to clog the thin slot - just in case it hampered heater performance.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfq2L-MNsuNB2ry4cmil1yAQaF7y-IhASUlmX2OQjYDx7EKmPqP4U6kQDsyXK5jD1dHdp9c_IY6dnh3WSFrrw_q4KqzNiIgmppEyRt5-aKrMrgFVistzUtAOHXj9zazpDANWTEii38haJDEnBhTIFfcSrtOyfjbiMSGBEskehTzhHFXmp9LYQngw/s4032/IMG_5803.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfq2L-MNsuNB2ry4cmil1yAQaF7y-IhASUlmX2OQjYDx7EKmPqP4U6kQDsyXK5jD1dHdp9c_IY6dnh3WSFrrw_q4KqzNiIgmppEyRt5-aKrMrgFVistzUtAOHXj9zazpDANWTEii38haJDEnBhTIFfcSrtOyfjbiMSGBEskehTzhHFXmp9LYQngw/w400-h300/IMG_5803.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">New 'O' ring (note old mole grip marks!)</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The spindle just pushes into the body. There was a small pocket of trapped air at the end that initially prevented the spindle pushing home, but that soon cleared.The body seems to have a groove in the end of it as though there should be a second seal to cushion it on the backplate. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGXt9O1LJkQiIBt9ZM75RZc2B8QDNcggu3StGFgpm2OzVhkjIFfJXhhYejIGdA5rIJSSGiHZ83dyyi97zRCzLMCG-Q6D4s0mTjmSw_Lnf6yUOtJ4IU2CN8tqjV7b0XOMpakUGKCBbqEl_WkGQC9ejKv763mQ-8ws17Pg1TQ8FYKMStd0JV_QtAVg/s4032/IMG_5804.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGXt9O1LJkQiIBt9ZM75RZc2B8QDNcggu3StGFgpm2OzVhkjIFfJXhhYejIGdA5rIJSSGiHZ83dyyi97zRCzLMCG-Q6D4s0mTjmSw_Lnf6yUOtJ4IU2CN8tqjV7b0XOMpakUGKCBbqEl_WkGQC9ejKv763mQ-8ws17Pg1TQ8FYKMStd0JV_QtAVg/w400-h300/IMG_5804.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Groove for a second seal?</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Mine didn't have a second 'O' ring but I will investigate that further and can always fit one later. So in the meantime </span><span style="font-family: arial;">I refitted the backing plate to the bulkhead and then the valve to the plate. If you are also refitting the backing plate, note that it's easy to orientate it wrongly. It needs to be fitted so that the holes that hold the valve are at top and bottom (north and south).</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6QIV20_BeVhwETQ2nT4ZaacuYXLnHoJE-LA1LYMG77E7zGTO9ZGxYgvWb5nvhjBnmw8AVDjfJxbyo7fk07Mqc8Lc05DjODKBhGeEFcGrtARYmRv3eqpavMvSWkxGkD21lz5jBHQPZ1Ktvh4T6tdy41JtUNzCzZlDNtphcCbXeyyZNkqi8iaep_A/s4032/IMG_5806.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6QIV20_BeVhwETQ2nT4ZaacuYXLnHoJE-LA1LYMG77E7zGTO9ZGxYgvWb5nvhjBnmw8AVDjfJxbyo7fk07Mqc8Lc05DjODKBhGeEFcGrtARYmRv3eqpavMvSWkxGkD21lz5jBHQPZ1Ktvh4T6tdy41JtUNzCzZlDNtphcCbXeyyZNkqi8iaep_A/w400-h300/IMG_5806.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Backing plate and valve refitted.</span></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq9S65Kk0wBN2pcx86zY3lApj8OkIJPpMZzaJ708FCz-Con6qAckrnzlbfX8g6btvbr_6r2QwqsNwl-LNg8cs2Q-OiMHzfjlQCT3VHWohPQ05o6uBx-Om5Ps8-4aUGOSG8odYGkk8aorBjxIbhSwBHOk3VIuvQBG5qY9PSa6lPvnIUrOa86WeyFw/s3513/IMG_5813%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2744" data-original-width="3513" height="313" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq9S65Kk0wBN2pcx86zY3lApj8OkIJPpMZzaJ708FCz-Con6qAckrnzlbfX8g6btvbr_6r2QwqsNwl-LNg8cs2Q-OiMHzfjlQCT3VHWohPQ05o6uBx-Om5Ps8-4aUGOSG8odYGkk8aorBjxIbhSwBHOk3VIuvQBG5qY9PSa6lPvnIUrOa86WeyFw/w400-h313/IMG_5813%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">It looks (and works) a lot better than it did</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">If your engine is still in the car and you are trying to refit the valve, I've read a tip that supposedly make things easier. It's in the "Goddess" book by Charles Vyse. He suggests </span><span style="font-family: arial;">feeding a piece of string through the hole in the bulkhead where the valve spindle/ knob will fit, and then trailing the string down to the ground on the engine bay side. You then tie the string to the valve and tug it back into it's approximate position from inside the cabin.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">It would make sense to be tying the string to the threaded tip. Partly for grip but also because it's a smaller dimension because of the flatted side. </span><span style="font-family: arial;">Also bear in mind that you will have/ should have two rubber hoses connected to the valve - which may make it heavier and harder to manoeuvre. Lastly, </span><span style="font-family: arial;">t's also worth noting that the valve assembly needs to be almost perpendicular to pass through the bulkhead hole - so some final fiddling and aligning on both sides of the bulkhead are probably called for. </span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsH7fJnmPA1QX5bmp7CFUjAN7HKLRiqga0mBNKJ3jiVycWg0DjRYBybndApa2s-B66PszS3vAguBIXewgcuG8_mfp58QGNpadwAkc8eVpHIxUrOEKZSqCdq4wH7ha-s9AYaXWmF_toT2tgXz9DPDvDWeFY-nCYUhj0uPdbapGeh1akrapeblZ52A/s4032/IMG_5820.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsH7fJnmPA1QX5bmp7CFUjAN7HKLRiqga0mBNKJ3jiVycWg0DjRYBybndApa2s-B66PszS3vAguBIXewgcuG8_mfp58QGNpadwAkc8eVpHIxUrOEKZSqCdq4wH7ha-s9AYaXWmF_toT2tgXz9DPDvDWeFY-nCYUhj0uPdbapGeh1akrapeblZ52A/w400-h300/IMG_5820.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The valve has to be turned through almost 90 degrees<br /> to locate it in the bulkhead</span></td></tr></tbody></table><div style="text-align: justify;"><span style="font-family: arial;">That's about as far as I can go until I put all the carpets back in, but I can show you how it all goes back together. It really just the reverse of removal. The indicator plate is fitted over the carpeting.</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCtXqFeEHpBgqiNy0k7kz6iCiM9kC2ShJ_XnmSjyEmnnBXx3ErTlUAz2tNKgx8YTeyaLhHuUTTZBt6mPn625sBELi-CarLpD-X_DZyIP-YuESxrfN4UkdRHOgLxnI6wrm5mVYFF-HoISaLX9tPiSznEJsTrXcPfyaIeQO5Ox45zUonc8qjIlvSgw/s4032/IMG_5834.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCtXqFeEHpBgqiNy0k7kz6iCiM9kC2ShJ_XnmSjyEmnnBXx3ErTlUAz2tNKgx8YTeyaLhHuUTTZBt6mPn625sBELi-CarLpD-X_DZyIP-YuESxrfN4UkdRHOgLxnI6wrm5mVYFF-HoISaLX9tPiSznEJsTrXcPfyaIeQO5Ox45zUonc8qjIlvSgw/w400-h300/IMG_5834.JPG" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">The 'stop' is fitted on the spindle......</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9Vw4b4W2jFvdJ9CdyKC5OTK2VpNgpQW1UZ8446oqt2pELNTxQQ1ne7VoXTaLugqo3p9DKBQ9ycRhUVwuFpJDjxmuXGbFVgmW777miiurLXLPOSxK0IM6G1__KZ0XYVptKSmNYucRzOAWHrosKzdE77NZBZ2cYqJKfiSaf1Z8Zv0L_sEeG0aSPcg/s4032/IMG_5835.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9Vw4b4W2jFvdJ9CdyKC5OTK2VpNgpQW1UZ8446oqt2pELNTxQQ1ne7VoXTaLugqo3p9DKBQ9ycRhUVwuFpJDjxmuXGbFVgmW777miiurLXLPOSxK0IM6G1__KZ0XYVptKSmNYucRzOAWHrosKzdE77NZBZ2cYqJKfiSaf1Z8Zv0L_sEeG0aSPcg/w400-h300/IMG_5835.JPG" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">.....and then the indicator disc is fitted over the stop.</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtSap4BShR1ZvezmdLjvq72dKDFT8u7i1x2grT4blaVoB4hPoNQBEuitglevQupOOtJMDUJt_yTp4-7JodmXDGAmWYKUsJESWaNcPAHOOxRvmBYUyZrrhhur5VqKJeBXalTpK6gLORVqLuCtFmb4HksjG0jBJ_hnZYJFBgbGQ_mYGbUBZ203YJLQ/s4032/IMG_5836.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtSap4BShR1ZvezmdLjvq72dKDFT8u7i1x2grT4blaVoB4hPoNQBEuitglevQupOOtJMDUJt_yTp4-7JodmXDGAmWYKUsJESWaNcPAHOOxRvmBYUyZrrhhur5VqKJeBXalTpK6gLORVqLuCtFmb4HksjG0jBJ_hnZYJFBgbGQ_mYGbUBZ203YJLQ/w400-h300/IMG_5836.JPG" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">Next comes the knob. At this point, orientate the knob (and spindle) so that the stop only allows it to rotate between the 'hot' and 'cold' positions. When you are happy, refit the grip washer and nut and refit the cover (small disc or rubber knob) according to what model you have.</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLs8IMGwNgixLSrH0--6OMkguiEJ0wctwnKbiLYaYP1PIDxo0ILO3DbRlDH5VMhccQQ65o1z-EU8GIUdRDm9XNAv35RpCPSL01RAHKF0YLh99ZuuDee2JpbcAzYXAlaTUi8k4UfnwLK6otxzcSGvqqq6R6G3CgdXdYaToltKYiCmreZ5gQVRgA5w/s4032/IMG_5838.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLs8IMGwNgixLSrH0--6OMkguiEJ0wctwnKbiLYaYP1PIDxo0ILO3DbRlDH5VMhccQQ65o1z-EU8GIUdRDm9XNAv35RpCPSL01RAHKF0YLh99ZuuDee2JpbcAzYXAlaTUi8k4UfnwLK6otxzcSGvqqq6R6G3CgdXdYaToltKYiCmreZ5gQVRgA5w/w400-h300/IMG_5838.JPG" width="400" /></a></div><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><br />Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-42110196993982421002022-11-13T20:44:00.003+00:002023-02-25T09:36:34.803+00:00Refitting The Engine Bay Pipes<div><div style="text-align: justify;"> <span style="font-family: arial;">I've been making good progress with replacing the piping and hoses at the front of the car.</span></div><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgp8jeSQDhlbJt40WP6Wjaph3xR4cT5NEEFv2La7-GgR2xH14i0UmnG9niepZT5_LnmhI73sn1Nnnx5EyTp0rEl73UCnZUiajddpSN24VhKIZ1vxOtAA1TRPAKvD0ss0_wmQHvmz34pVNTM7IEEAAnVbCbJcwc8_yLu1WssRZW5yaEip10fCWN--Q/s4032/IMG_5752.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgp8jeSQDhlbJt40WP6Wjaph3xR4cT5NEEFv2La7-GgR2xH14i0UmnG9niepZT5_LnmhI73sn1Nnnx5EyTp0rEl73UCnZUiajddpSN24VhKIZ1vxOtAA1TRPAKvD0ss0_wmQHvmz34pVNTM7IEEAAnVbCbJcwc8_yLu1WssRZW5yaEip10fCWN--Q/w400-h300/IMG_5752.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Nice to see some progress at last</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;">The job hasn't been particularly hard, it's just complicated and needs a bit of thought applying throughout. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzLwhzGy7ia98WqGlgxlpf-aAZ2lrF9iyUv7BFt6DvkR9K9gfsNs7OEt9aUvqDx5ZS6uIlab3okbYCc9W6jxJ7wkvNq8ELoIsbogmtu_3Ph4AWWUpa2SIwWZl_Mx2JELuUoZVgBgwXcfki6kjtskwpNyGtFSlqPmZrf_TunoG2cPfBQrp0wDi0xQ/s3264/IMG_0140.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzLwhzGy7ia98WqGlgxlpf-aAZ2lrF9iyUv7BFt6DvkR9K9gfsNs7OEt9aUvqDx5ZS6uIlab3okbYCc9W6jxJ7wkvNq8ELoIsbogmtu_3Ph4AWWUpa2SIwWZl_Mx2JELuUoZVgBgwXcfki6kjtskwpNyGtFSlqPmZrf_TunoG2cPfBQrp0wDi0xQ/w400-h300/IMG_0140.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">It all happened on the left side of the car.....</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I've written a post before about pipes and pipe seals. You can find that <a href="https://ds-restoration.blogspot.com/2018/10/a-quick-word-abouthydraulic-fixings-and.html" target="_blank">HERE</a>. It's worth repeating some of that earlier post. I can't really explain how I put everything back, as it's a bit of 'journey to discovery' and, if you do this, your journey will be different to mine. I can offer some tips and personal thoughts though.</span></div><div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><span style="font-family: arial;"><div style="text-align: justify;"><b>BEFORE DISMANTLING</b></div></span></div><div style="text-align: justify;"><span style="font-family: arial;">Before you even consider taking the pipework apart, ask yourself 'why?' What do you want or need to achieve? Is there another way of getting what you want? Are you trying to replace a particular pipe? Could you just remove that one or will others need to come off. If something goes wrong, how will you salvage the situation. What is 'Plan B'? Will the car be stuck somewhere - a long way from a garage and help?</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Take LOTS of reference photos. Photograph all angles. You'll still wish you'd taken more. </span><span style="font-family: arial;">Clean off any loose muck so that you are clearer about what you are looking at.</span></div><div style="text-align: justify;"><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVGtuHCGNtOLYL1Sg3XDIXPC_is3H1OjKbLTvB9bFVKa8oaOx3t6Q2LqgubVmxas-57XqqMRRFLP-Swmd3RfoXLY8j42IELbl1TtdMqMSO9CisK_b-Ua0NLG-nR_BGrP94zBsXFfBg8eQqPVWpnEh1_0I6BTxayRhMLm-5XuAH2pRMd806IZlLmA/s3264/IMG_0697.JPG"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVGtuHCGNtOLYL1Sg3XDIXPC_is3H1OjKbLTvB9bFVKa8oaOx3t6Q2LqgubVmxas-57XqqMRRFLP-Swmd3RfoXLY8j42IELbl1TtdMqMSO9CisK_b-Ua0NLG-nR_BGrP94zBsXFfBg8eQqPVWpnEh1_0I6BTxayRhMLm-5XuAH2pRMd806IZlLmA/w400-h300/IMG_0697.JPG" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">Follow pipes and hoses through from the engine bay into the wheel arch and vice versa - taking photos as you go. </span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuVOdclGkJ_OFI5Tw8hDwJWjTCAx56Odr0w4GZu1v3JXYDbwXAT1AGfn9sO4ABWsb9evfGSbam6dondOcuK5eaCBEJfmBM_5MWQfM92NvyJjyHO4G37kBqw0pDUYDtKXI_ImdmTiXO0FbciaCTx85WfW9WabXvoFNb-XSTuAsY3T361cZqOTpyYg/s3264/IMG_0642.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuVOdclGkJ_OFI5Tw8hDwJWjTCAx56Odr0w4GZu1v3JXYDbwXAT1AGfn9sO4ABWsb9evfGSbam6dondOcuK5eaCBEJfmBM_5MWQfM92NvyJjyHO4G37kBqw0pDUYDtKXI_ImdmTiXO0FbciaCTx85WfW9WabXvoFNb-XSTuAsY3T361cZqOTpyYg/w400-h300/IMG_0642.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">This pipe and hose in the wheel arch........</span></td></tr></tbody></table></div></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpEF5nJFmsTD6nqZws75_zrl3w1QoilU8GJS0Y--3W1LaiI1ECKdG-UqYM2JT8VumEd-eD51pPamSyvmtQMKYJNNIHkINjVLnimTHHbUCHftbszek10M0FglMukafByI4ofe1kBdSUEC6LkOt5FEyfz_EqSUMmG4rrBpevvZhcw2g4wIsIdSUSnA/s3264/IMG_0641.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpEF5nJFmsTD6nqZws75_zrl3w1QoilU8GJS0Y--3W1LaiI1ECKdG-UqYM2JT8VumEd-eD51pPamSyvmtQMKYJNNIHkINjVLnimTHHbUCHftbszek10M0FglMukafByI4ofe1kBdSUEC6LkOt5FEyfz_EqSUMmG4rrBpevvZhcw2g4wIsIdSUSnA/w400-h300/IMG_0641.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">.....comes out here in the engine bay</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Note which pipes sit in front of, or above other pipes. Where are the pipes clipped in place and how. There are several different types of clip and sizes of rubber bushes fitted.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEic4bzI9IapGP1imXq_4tPVw5Xbkgwd3qDgJUORtzd9ZBuGqsox8QVfE9hIg0j3UK5KrcoUeUvgDAZqX4cjjDVszNU_9CR2CISMqoGtNU7TJkuQ9xPHBCu08Zns98mQfGUutxUwTRTw91Bsr-7PCy_srLzztClKyHeNuqhrvRxHDYI050FP73xseQ/s3264/IMG_0613.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEic4bzI9IapGP1imXq_4tPVw5Xbkgwd3qDgJUORtzd9ZBuGqsox8QVfE9hIg0j3UK5KrcoUeUvgDAZqX4cjjDVszNU_9CR2CISMqoGtNU7TJkuQ9xPHBCu08Zns98mQfGUutxUwTRTw91Bsr-7PCy_srLzztClKyHeNuqhrvRxHDYI050FP73xseQ/w400-h300/IMG_0613.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Various clips and brackets</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Despite thinking the photos I'd taken would be a good memory jog, I still found myself asking what on earth a lot of them were trying to show and why I'd felt they were relevant.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLPxKZogFLwVj7cjTWdd-5f-xa9LV8Vf3oeLtp6CR_VmbxDUfOr3jjriu7BBqJlUpSqLeJKeix3mgxyMXckJAoQENj0QAmyjAKFlnOk_fRtOqy02WZgd0xsLh3LoAm0yXmQ8GJ57N6gt6MZsYwYpxPNhTsS8pgBofpANatIfEiisO7lHnkML734w/s3264/IMG_0647.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLPxKZogFLwVj7cjTWdd-5f-xa9LV8Vf3oeLtp6CR_VmbxDUfOr3jjriu7BBqJlUpSqLeJKeix3mgxyMXckJAoQENj0QAmyjAKFlnOk_fRtOqy02WZgd0xsLh3LoAm0yXmQ8GJ57N6gt6MZsYwYpxPNhTsS8pgBofpANatIfEiisO7lHnkML734w/w400-h300/IMG_0647.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Me, pointing at something meaningfully......</span></td></tr></tbody></table></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;"><b>DISMANTLING</b></span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Be clean. </b>Try to remove as much loose muck as you can while all the pipes are in place.</span><span style="font-family: arial;"> </span><span style="font-family: arial;">Especially around the flare nuts. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNAkJogAmaCz8_nQ0LHL2Ff8z0lnZQNC_hJ1D37VXapOWEDn_H8_MeuXbWf1p4Iv7e8wIl_UQ8s5RD_ZoOAnyltA9kGjgN1x_xPHA0zjGWIR3SsIx0sqtrTWjSpceCkKMUgFrVaJHqiv4iuo9tnf4Mta9-qJqYlhErKqvMl4IMS21Q3Tbs0zGnsw/s3264/IMG_0661.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNAkJogAmaCz8_nQ0LHL2Ff8z0lnZQNC_hJ1D37VXapOWEDn_H8_MeuXbWf1p4Iv7e8wIl_UQ8s5RD_ZoOAnyltA9kGjgN1x_xPHA0zjGWIR3SsIx0sqtrTWjSpceCkKMUgFrVaJHqiv4iuo9tnf4Mta9-qJqYlhErKqvMl4IMS21Q3Tbs0zGnsw/w400-h300/IMG_0661.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Mucky pipes</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Depending on how big a job you have set yourself, you almost certainly want to avoid grit and road dirt falling into fittings and pipe ends. Also, cleaning the flare nuts up means that you are less likely to damage them when trying to undo them.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Be thoughtful and patient.</b> Think of the job as a puzzle. Don't just dive in. How are the pipes layered and routed? Check the fitting at both ends to decide. Which pipes need to come off first to then allow access to other pipes? Target them methodically.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnbNlnRovBDDcOaCqXjJaI-7rF09S9TWRjSVsV-3hlWasrNxBiTQLkUWDN4FHap3e_90LNilAmxl9S1URvNKW0uDdr-AJRVESLDkZ33yTd7xUCc2WyCtiZMgm3T3WM7FY-D2AERScl0jGzxpdXfbsnkwhMScGIQvaKX0MiP6jywNJ64GEy_l8ENQ/s3264/IMG_0123.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnbNlnRovBDDcOaCqXjJaI-7rF09S9TWRjSVsV-3hlWasrNxBiTQLkUWDN4FHap3e_90LNilAmxl9S1URvNKW0uDdr-AJRVESLDkZ33yTd7xUCc2WyCtiZMgm3T3WM7FY-D2AERScl0jGzxpdXfbsnkwhMScGIQvaKX0MiP6jywNJ64GEy_l8ENQ/w400-h300/IMG_0123.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Work tactically: target a pipe then remove it</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">You might find that some of the pipe flare nuts are rusted. This might meant they are harder to undo, but also that their hex heads are weakened - as, potentially, are the pipes they hold in place. Try to avoid rounding a hex head and giving yourself another problem. Also, rounded hex heads often leads to broken pipes. Yet another problem to be dealt with.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Use the right tools. </b></span><span style="font-family: arial;">As opposed to an open-ended spanner, a proper flare nut spanner will grip the hex on most sides and is </span><span style="font-family: arial;">less likely to slip off and star</span><span style="font-family: arial;">t rounding edges. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPDQfsHhx4q0tV2lnRm67z2S2FE9ZGibBGaAUmBZ0GcGcmC65Yt782CeErqsTLTCWTwnW7cpOCTM5Lnz3DslG1EvEI3NpRwKdjGT8sc6P30lui044nSJmp_nBJZrc86nzBeSyzwdnELd02T-tZOdWRVkZWuBXGY39RhirLO-564FOXVa3FSNDBug/s1600/IMG_8216.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPDQfsHhx4q0tV2lnRm67z2S2FE9ZGibBGaAUmBZ0GcGcmC65Yt782CeErqsTLTCWTwnW7cpOCTM5Lnz3DslG1EvEI3NpRwKdjGT8sc6P30lui044nSJmp_nBJZrc86nzBeSyzwdnELd02T-tZOdWRVkZWuBXGY39RhirLO-564FOXVa3FSNDBug/w400-h300/IMG_8216.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">A flare nut spanner grips the nut securely</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">For original Citroen flare nuts, you'll need a 9mm and 12mm spanner. </span><span style="font-family: arial;">You can even buy ratchet flare nut spanners. They are chunky - so not practical in tight spaces, and fiddly to remove after you've used them. But when in use, they make tightening and loosening much faster as you don't need to lift-off and relocate the spanner ever partial turn.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQhmqvVqmRcULO60hBvB7cxEiNnJUdfTMyVgIiFnzju9HLwQbUE_1Q7IiyLeX5WHmR2Tnda10p1pucFBxrv_9z27GjICG8thcG-S_iqhr1OmGXP9o2Q8Nv-NNQuYnLMnWsRKh92GVe2LgRNwQ2ChRcws5XBO_FLXy5PjmENAOfeYedgIAdXrLDKg/s4032/IMG_5788.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQhmqvVqmRcULO60hBvB7cxEiNnJUdfTMyVgIiFnzju9HLwQbUE_1Q7IiyLeX5WHmR2Tnda10p1pucFBxrv_9z27GjICG8thcG-S_iqhr1OmGXP9o2Q8Nv-NNQuYnLMnWsRKh92GVe2LgRNwQ2ChRcws5XBO_FLXy5PjmENAOfeYedgIAdXrLDKg/w400-h300/IMG_5788.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Flare nut spanners</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">As the 9mm nuts are prone to rusting, some after market nuts have a 10mm hex head.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis7QhjqNIQn6EhXWWxkOzKe5-966c2wC597Q9zPf7pf0vnYLkfssni8qs4v8NqYbGwqzV-tbCRDzY8wGIbwW3dgPaUEjSUt_ZiaJeS1bBw5tx2k1OSPeWYorZOpdipd0XU31Dw31C1SGCkUgiT0rJKl8R_BIz0TmVAfNfyKFj-Qrdo7pZ_oxrrhg/s3558/IMG_5784.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2613" data-original-width="3558" height="294" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis7QhjqNIQn6EhXWWxkOzKe5-966c2wC597Q9zPf7pf0vnYLkfssni8qs4v8NqYbGwqzV-tbCRDzY8wGIbwW3dgPaUEjSUt_ZiaJeS1bBw5tx2k1OSPeWYorZOpdipd0XU31Dw31C1SGCkUgiT0rJKl8R_BIz0TmVAfNfyKFj-Qrdo7pZ_oxrrhg/w400-h294/IMG_5784.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">9mm and 10mm hex ended flare nuts</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">For a hex nut to release and undo, it needs to be able to move along the pipe a little. If the pipe is bent close to the flare nut, it won't have scope to move. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTKRx_Zu6yZgMYRe0M6tXTRHb0L_OxnFwDvJzyWA1FFMOoxzKRycFKA4xIaHJeARQJq3omy3iC6GsmBWUvOlIeNFkbKM4hjd0wnKamUpZMKEhgRLSD3Omqul29PnuRCHUPIoHkHwEpghBmnhKs0Vc5Cy5TEWLu_vnKYK0-JbZgfDlVX8ScnXdiBQ/s1600/IMG_8201.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgTKRx_Zu6yZgMYRe0M6tXTRHb0L_OxnFwDvJzyWA1FFMOoxzKRycFKA4xIaHJeARQJq3omy3iC6GsmBWUvOlIeNFkbKM4hjd0wnKamUpZMKEhgRLSD3Omqul29PnuRCHUPIoHkHwEpghBmnhKs0Vc5Cy5TEWLu_vnKYK0-JbZgfDlVX8ScnXdiBQ/w400-h300/IMG_8201.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">A bent pipe can prevent the flare nut releasing</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">If you can, gently straighten the last 20mm or so of pipe close to the flare nut - so that the pipe is entering straight into the fixing.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi89cY79lCN_iwH6RATJkz3kwVDcyxEhqtlvQyVkmWjCfZjCS_CNiZKVlE5re-AfeUBWUpPmXg1rMpMME8BLX7RvdXfCXB6l5qa3X1fcSsEjPlWZCNgClaELGLRoYCYK82yCts2QtA5ND80XNTSDH4LSKyJFxh9dhbY3UwJKQrSN325K5fOzNLpDA/s1600/IMG_8183.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi89cY79lCN_iwH6RATJkz3kwVDcyxEhqtlvQyVkmWjCfZjCS_CNiZKVlE5re-AfeUBWUpPmXg1rMpMME8BLX7RvdXfCXB6l5qa3X1fcSsEjPlWZCNgClaELGLRoYCYK82yCts2QtA5ND80XNTSDH4LSKyJFxh9dhbY3UwJKQrSN325K5fOzNLpDA/w400-h300/IMG_8183.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: small;">A straight end makes things easier</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><b style="font-family: arial;">Know your enemy. </b><span style="font-family: arial;">Some pipes are 'simple': they have a flare and flare nut at each end. If they are damaged and need to be replaced, it's very easy to make a replacement up - or to get someone with the right tools to do it. In the UK, 'cuprinol' (aka cupro-nickel tubing) is used for this purpose. It's nearly as strong as the original pipe (perfectly fine for Citroen high pressure hydraulics) but is more malleable and easier to shape. </span></div><div style="text-align: justify;"><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;">Others pipes on a DS are more complex: Some ends are silver-soldered into special fittings.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEheqAIkEQ473D23Ud_0NmwvEY9AFoG4JumSEYxKmdBkCUuBxAOuSu4x4RaPv5rfkJ4pNmqm0H2r3WiyoCmmd-fGnhf69dCTUroEPqrGYjB2Ai9WsVTNjELX4R0Kd9E7-Z0ajSc1WMZyIZZuRIgahD0uyrhjgRKSRX-WreuVG-1CIAiO4AFXp7Zqww/s3264/IMG_0737%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEheqAIkEQ473D23Ud_0NmwvEY9AFoG4JumSEYxKmdBkCUuBxAOuSu4x4RaPv5rfkJ4pNmqm0H2r3WiyoCmmd-fGnhf69dCTUroEPqrGYjB2Ai9WsVTNjELX4R0Kd9E7-Z0ajSc1WMZyIZZuRIgahD0uyrhjgRKSRX-WreuVG-1CIAiO4AFXp7Zqww/w400-h300/IMG_0737%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Pipes with a fitting plate attached</span></td></tr></tbody></table></div><div><span style="font-family: arial;">If these pipes get damaged, they are much harder to repair as the fittings need to be heated red hot for repairs and </span><span style="font-family: arial;">cuprous-nickel pipe becomes soft and unstable at such temperatures. Be warned and take extra care of such fittings. Some/ many are available as replacement parts but are costly and may not fit your car: D plumbing varied over the years and across models/ specification. </span></div><div><br /></div></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Be gentle. </b>You should not have to bend any of the pipes to remove them. With a little care and thought, they can be manipulated out. You will need to loosen or remove brackets, and you may need to loosen components. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQYPANVOjsFlMJ6lg-sU_WMwbBvLiQB5vRRUzCfnArv1xA-Pl1swtAzQq98KSyoY8c8n8S-PEPhVL-qz4O8lL5eQ9UteZDT_tvfiNNlUTeJ_LTHLBRHKWt6FDYjkF24inzeih4NFr9PMTXUQrLgvlLM4MtrFbbhntqhdWT0b1WjSBWxL6ww-xBRg/s3264/IMG_0614.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQYPANVOjsFlMJ6lg-sU_WMwbBvLiQB5vRRUzCfnArv1xA-Pl1swtAzQq98KSyoY8c8n8S-PEPhVL-qz4O8lL5eQ9UteZDT_tvfiNNlUTeJ_LTHLBRHKWt6FDYjkF24inzeih4NFr9PMTXUQrLgvlLM4MtrFbbhntqhdWT0b1WjSBWxL6ww-xBRg/w400-h300/IMG_0614.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Pipe clamps</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">You may need to 'flex' a pipe, but avoid bending and re-shaping. You risk weakening the pipes and, if the shape is changed, may also lose track of where it was meant to go.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Be thorough. </b></span><span style="font-family: arial;">If you are only removing some pipes, or removing pipes from components, be aware that there will be little probably be shards of the old pipe seal left in the fitting or component. You will need to hook those (and any stray pipes seals) out before you put things back together.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj50yfHY8JEOmMvcuUVl9LzbJomtNiAo3m_kbtNMU1-o8TkEBhGXhCWgz59svdVAg2qlmUhmownJKFgvfErgDbX4630UU7JOawqCUZ8UCkawaHJXeO2bfO05H3F8b6NsT8a3Ou1gmYl5hDWtEtNGOVsTnfsSL5nE3Z4fBV86qJwOlfRbnZqMRKS6A/s1600/IMG_8204.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj50yfHY8JEOmMvcuUVl9LzbJomtNiAo3m_kbtNMU1-o8TkEBhGXhCWgz59svdVAg2qlmUhmownJKFgvfErgDbX4630UU7JOawqCUZ8UCkawaHJXeO2bfO05H3F8b6NsT8a3Ou1gmYl5hDWtEtNGOVsTnfsSL5nE3Z4fBV86qJwOlfRbnZqMRKS6A/w400-h300/IMG_8204.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Removing pipe seals leaves slivers of rubber</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><b style="font-family: arial;">Be organised. </b><span style="font-family: arial;">Try to label up the pipe ends in some way for easier identification. Come up with a system that works for you. My system worked for me. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU1H8ATmk4IlsLvQ7s0LL5_xvLvfqKGyNDWmjEwCgZQ2-L2VaX_iGoFmu3yKHRDr261OoHZFzttIoG7gDsY17KOrOnUA-N01i6FwStA25Frpe9sUqKFxyhjZhN09K1wJmr3vSxlYrRvnmpw-apypGRF9AoMEHc9Lc5YB8lkdjdKw2mHgTSkBHLVA/s3264/IMG_0591.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjU1H8ATmk4IlsLvQ7s0LL5_xvLvfqKGyNDWmjEwCgZQ2-L2VaX_iGoFmu3yKHRDr261OoHZFzttIoG7gDsY17KOrOnUA-N01i6FwStA25Frpe9sUqKFxyhjZhN09K1wJmr3vSxlYrRvnmpw-apypGRF9AoMEHc9Lc5YB8lkdjdKw2mHgTSkBHLVA/w400-h300/IMG_0591.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">You can't have enough labels....(red means 'engine bay side')</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Well, the system worked most of the time anyway.....I still lost track of what my 'code' meant. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEildveHbLEVU-UhBqt4ami2ntFGQGXxDzNHoMH6cSJdJI9cZDXO9BYFETRGobQ49_2gZX8lJSFhtFadw9JHUBfz9fsxANHNqXGo37yLKe02sl8W7DRbYxu59nmKgutymvvwalYBbNM_9zIVZWzw4uOinGFRXCHuEqaJzF0fOuljj5YQtnvrMDJA/s4032/Jumble%201.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEildveHbLEVU-UhBqt4ami2ntFGQGXxDzNHoMH6cSJdJI9cZDXO9BYFETRGobQ49_2gZX8lJSFhtFadw9JHUBfz9fsxANHNqXGo37yLKe02sl8W7DRbYxu59nmKgutymvvwalYBbNM_9zIVZWzw4uOinGFRXCHuEqaJzF0fOuljj5YQtnvrMDJA/w400-h300/Jumble%201.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">It's easy to get confused.....</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">After I'd removed the pipes I separated them and catalogued them - taking even more reference photos. It pays to have a system.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSgYfEzeCqQAS2UOy9mtw9YIefB__dyEe9E-JWiYM2K0TxRjd3hx6COaZMXjfVkiHacsG2VKpqpK8rfQStFDA42LnRBOtbPLgeJjCXLAEeIsEU_FdV8hk8BNCmj8Rz0Zrhc7k4vIgwNjmsTprrks82nXU58ni1tKlzjdB8uwN9YXGm7QxNcNvgiQ/s4032/GG%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSgYfEzeCqQAS2UOy9mtw9YIefB__dyEe9E-JWiYM2K0TxRjd3hx6COaZMXjfVkiHacsG2VKpqpK8rfQStFDA42LnRBOtbPLgeJjCXLAEeIsEU_FdV8hk8BNCmj8Rz0Zrhc7k4vIgwNjmsTprrks82nXU58ni1tKlzjdB8uwN9YXGm7QxNcNvgiQ/w400-h300/GG%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">More cataloguing (green tag means 'wheel arch side')</span></td></tr></tbody></table></div><div style="text-align: justify;"><b style="font-family: arial;">Dealing with rubber hoses. </b><span style="font-family: arial;">Some pipes have hoses fitted to the end. </span><span style="font-family: arial;">If you car has been tampered with before, these may be held on with jubilee clips. Easy to undo. If they are original, they will have a steel belt and 'Mirex buckles on them.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYjJjRtLyT8_TBfTXygvlfNmi1DiNslVeuT0p67JkXwvRPgb5Pj3W-NZdu0Iis3BXv3s1Xojfzj0HC_sV3GtSXMB8XVoPOZzslBn4OAnz6I9Tmq2o6q1HSVRxg2S5h-7XL9y_JVaZzLjoKABoPqlF_NmrzrHWqQEPzIyd_mH8_Rddcy3t7rQ4VCA/s3264/IMG_0132.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYjJjRtLyT8_TBfTXygvlfNmi1DiNslVeuT0p67JkXwvRPgb5Pj3W-NZdu0Iis3BXv3s1Xojfzj0HC_sV3GtSXMB8XVoPOZzslBn4OAnz6I9Tmq2o6q1HSVRxg2S5h-7XL9y_JVaZzLjoKABoPqlF_NmrzrHWqQEPzIyd_mH8_Rddcy3t7rQ4VCA/w400-h300/IMG_0132.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Mirex buckles on hoses</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">These have been tightened with a key - a bit like a split pin. Removing them means loosening the pin (by unwinding a little) and then carefully dismantling the strap. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVxPimINe2_uB5459ALSkcvQgloT_EdDlhPKmRqVaUGb0UQnhHKhR5zW18WxTJQgbsTR35P1_Ri7a4VxmNxm3TJuFunrx16wNVQ9QQSjHJMI7eJwIIr_aSKPZ-anTMKRp8jt025HT-EGm-ZOX2PazArnjuOORR7EhrSlIlxc2OWCbXhCDnko72zw/s4032/IMG_5728.JPG" style="margin-left: auto; margin-right: auto;"><span style="font-family: arial; font-size: x-small;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVxPimINe2_uB5459ALSkcvQgloT_EdDlhPKmRqVaUGb0UQnhHKhR5zW18WxTJQgbsTR35P1_Ri7a4VxmNxm3TJuFunrx16wNVQ9QQSjHJMI7eJwIIr_aSKPZ-anTMKRp8jt025HT-EGm-ZOX2PazArnjuOORR7EhrSlIlxc2OWCbXhCDnko72zw/w400-h300/IMG_5728.JPG" width="400" /></span></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Removing a Mirex buckle and strap from a hose end.<br />(Note the protective collar)</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">If you are lucky, you will reach a point where the key - the split pin can be pulled out. </span><span style="font-family: arial;">Sometimes it's easier to remove a pipe with a hose still attached, and deal with it on the bench. </span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">The rubber hoses on Ds all have part numbers: they are of a size and length needed to do a particular job. length aside, in terms of internal and external diameters, they, by and large, conform to a few standard sizes. However there are a few hoses that are particularly special. Don't be tempted to cut the hose off and then deal with the stump end in due course. Firstly, you will possibly end up with a hose that is too short to do it's job. Secondly, not all the hoses are of a standard dimensions. How do I know? You can read all about that in my previous post......</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>CLEANING</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">Not a lot to say really. I thought about getting the parts vapour-blasted but my local workshop guy said it would be a long process to get all surfaces and angles covered and time meant money. Expensive. It also introduces gritty sand to hydraulic pipes. Probably not a good idea. Instead I gave all my parts a wash in Jizer and stippled them with a tooth brush and paint brush. I rinsed and dried them. I also put a wire brush over them all to clean off loose rust. At this point you need to take care not to bend or damage the pipes through rough handling.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I examined all the ends with flare nuts and carefully straightened any that were bent and prevented the flare nuts from moving a little along the pipe. I used emery cloth to gently de-burr ends to aid refitting. Similarly, I used a wire wheel to clean up the threads and hex ends of flare nuts. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I also rubbed over the pipes with wire wool. There were all washed again and I blew them through with compressed air. be aware that compressed air can have moisture in it and this can condense when you blow the wire through a cold pipe: cleaning the pipe can also introduce moisture. For this reason, I didn't seal the ends up completely after blowing them through.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">My pipes were left clean, but mottled and patchy. At this point I considered getting them all zinc-plated. I've found a good local plater and this was affordable so not out of the question. However the plating process involves the use of acid and I was concerned it might weaken old pipes. </span><span style="font-family: arial;">There was also the risk that the plater bend a few pipes along the way. </span><span style="font-family: arial;">I've also seen cheap, re-plated, pipes on sale in Holland. In many cases the flare nut has moved along the pipe during plating. When it's move to the end for fitting, it leaves a bald spot. I also noticed that plating accentuates old pox-marks on pipes and they never really come out looking 'new' - just 'odd'.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">If your pockets are deep, you can buy newly re-made pipes with fittings brazed to the ends. </span><span style="font-family: arial;">These certainly pass the 'shiny' test, but beware that they may not fit your car and it's not until it's in your hand and you compare it to the part you removed, that you realise it's a bit different.....</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtURKcFz5qUVBIWc6dECkagTzyA0xslZxKS6vfUhSJnWHX4fli9l0l8sTR4BUutt2fSpAeG3pOVwcoihpOVvp4kUhmqJPvjvYcASOea5dMr4OZS49d3d5EMqbPeqpuMz8fBZIyabWEgm2I020x4azpXX7sRzTehgR8XPtT-kI9fhZMXC2Ba9DZWQ/s1330/prefabricated.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="819" data-original-width="1330" height="246" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtURKcFz5qUVBIWc6dECkagTzyA0xslZxKS6vfUhSJnWHX4fli9l0l8sTR4BUutt2fSpAeG3pOVwcoihpOVvp4kUhmqJPvjvYcASOea5dMr4OZS49d3d5EMqbPeqpuMz8fBZIyabWEgm2I020x4azpXX7sRzTehgR8XPtT-kI9fhZMXC2Ba9DZWQ/w400-h246/prefabricated.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">New pipes. From 'Der Franzose' in this case</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The original Citroen pipes with fittings on the end have a different appearance to the 'simple' pipes. I</span><span style="font-family: arial;"> </span><span style="font-family: arial;">wonder if they are made of a different material, or are perhaps copper plated to help the silver-solder joint process?? I've brought brand new old stock original Citroen pipes and they are that way from new.</span><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7QupTJkkNzZGVxEqyLVNsPta8QjVxVs5Yvfp6RGaa-m6esj_zDYnbxQpEjJAdU5ofS6fecCbySNF-rdIOxwBOGr8Uw3ZjqYgQSJNyQi2hDdDAwF28rN7rq-SDsv4OSn6hgfNs3mpwomOUEO6J8QgQvxJ_W9J82xDUETks-PiUINqKnqK82irXbQ/s3264/IMG_8144.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7QupTJkkNzZGVxEqyLVNsPta8QjVxVs5Yvfp6RGaa-m6esj_zDYnbxQpEjJAdU5ofS6fecCbySNF-rdIOxwBOGr8Uw3ZjqYgQSJNyQi2hDdDAwF28rN7rq-SDsv4OSn6hgfNs3mpwomOUEO6J8QgQvxJ_W9J82xDUETks-PiUINqKnqK82irXbQ/w400-h300/IMG_8144.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">A 'new old stock' pipe with a copper finish</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhronRIFDGA6OXCll_SJiNcRtqxt7WxOvCxMW2KEwXDTpyrv6SwDyHPlPYBagcBgkbKDaeR69l49VuxyNppdMOnQ1vd11TLai5brQpW2jt6NUxXgQLrloFdFIIVTYpqk7PwsvO3FGqb4m7VRyW62cQEe-PEuIkfL1_pD_HHai7yzZnixB2Oyfz8tQ/s1010/copper%20coloured.jpeg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="670" data-original-width="1010" height="265" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhronRIFDGA6OXCll_SJiNcRtqxt7WxOvCxMW2KEwXDTpyrv6SwDyHPlPYBagcBgkbKDaeR69l49VuxyNppdMOnQ1vd11TLai5brQpW2jt6NUxXgQLrloFdFIIVTYpqk7PwsvO3FGqb4m7VRyW62cQEe-PEuIkfL1_pD_HHai7yzZnixB2Oyfz8tQ/w400-h265/copper%20coloured.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Another original 'new old stock' pipe (photo credit Citrotech)</span><br /></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAi_gEQtMbOJftx8uAivQd3Bgix9BAAYyJB1WKWWnalF68Tl0diEpC21wml71z8R7pawIyZy2GZKQnJ9zdUfH-KUybsg3g3G3EIFCHN5LRCm9zKl1vsEDrknXuKEBJDTHGR3_rsuR5GuA3TMOWjtoiNXHeKXM8MiD9JoROdvrNC_Jfgk8Y1UjGlw/s788/1.jpeg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="588" data-original-width="788" height="299" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAi_gEQtMbOJftx8uAivQd3Bgix9BAAYyJB1WKWWnalF68Tl0diEpC21wml71z8R7pawIyZy2GZKQnJ9zdUfH-KUybsg3g3G3EIFCHN5LRCm9zKl1vsEDrknXuKEBJDTHGR3_rsuR5GuA3TMOWjtoiNXHeKXM8MiD9JoROdvrNC_Jfgk8Y1UjGlw/w400-h299/1.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">And it's modern, reproduction, equivalent (photo credit: Citrotech)</span></td></tr></tbody></table></span></div><div style="text-align: justify;"><span style="font-family: arial;"> </span></div><div style="text-align: justify;"><span style="font-family: arial;"> So it looked as though they weren't originally shiny zinc anyway?</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Lastly I thought about my use of the car. I plan to take care of it and keep an eye on it. In the end I just decided to rub my pipes and flare nuts over with an oily rag to give them some resistance to moisture and rust.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Hoses were washed in Jizer and inspected for cracks, cuts or rub marks. They all passed the test. They had lost some flexibility and had become a little stiff but were perfectly serviceable - especially as they are for the low pressure return circuit.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>REFITTING.....</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">.......Is the reverse of removal. In many ways it is. You need to be organised, thoughtful, careful, gentle etc. Above all you need to be methodical and study your photos. Consider starting with the pipes that seem to be buried deepest. Which ones would then go on top of them? Some trial and error is involved.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><div><span style="font-family: arial;"><b>Pipe seals and 'O' rings'. </b>You will need plenty of pipe seals....and it's always good to have spares in case you need to disassemble a pipe to shift things around a bit. You will need a lot of the ones for 4.5mm pipe, and at least three or four seals for 6.35mm pipe. For these 6.35mm pipe seals, most will need to have an outer diameter of 10mm, but if your car has a brake accumulator sphere, the seal at that end of the pipe needs to have a 12mm outer diameter.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhj1-iEC1J4_5WDqkkqHCZSwflFj4YLju1AQGf1ugC-xJYP5Jx6iQhqthUeXE1R1x1jHE34TNMxKQE_lHD0v5Bk7_TNxl9zDkR0rbLl_R8opSN-wtAyDwr2tVmjw_levnXUdStTzHEm0lVUeyVqqY5oucRCheoXR9TPRc6XVNbugUu9_nRBvKlJtg/s3264/IMG_8221.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhj1-iEC1J4_5WDqkkqHCZSwflFj4YLju1AQGf1ugC-xJYP5Jx6iQhqthUeXE1R1x1jHE34TNMxKQE_lHD0v5Bk7_TNxl9zDkR0rbLl_R8opSN-wtAyDwr2tVmjw_levnXUdStTzHEm0lVUeyVqqY5oucRCheoXR9TPRc6XVNbugUu9_nRBvKlJtg/w400-h300/IMG_8221.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">A selection of seals</span></td></tr></tbody></table></div><div><span style="font-family: arial;">The original small 'o' rings that sit inside plate seals were painted white on one side. The painted side was meant to face towards the direction of fluid flow. Perhaps the rings were 'o' shaped at all and had a different profile? </span></div></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSq8yCReTveiZTsTwo1IcdFSscgpG4NRx3u6b_GmlS7uMe2ZVP35po9yILKcuqRLgzG2TMZAzr3fbkZm_oMFKDvWlVBftbanq3Q8TiE1rqVxqECgOD_Nk4RTMTcuZi9u0iF5F4gVhlKrdq6sfEuXWiW7XGFuZZmascD1B-de1Hj0sm_Qk4b1jwPw/s1600/IMG_8189.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSq8yCReTveiZTsTwo1IcdFSscgpG4NRx3u6b_GmlS7uMe2ZVP35po9yILKcuqRLgzG2TMZAzr3fbkZm_oMFKDvWlVBftbanq3Q8TiE1rqVxqECgOD_Nk4RTMTcuZi9u0iF5F4gVhlKrdq6sfEuXWiW7XGFuZZmascD1B-de1Hj0sm_Qk4b1jwPw/w400-h300/IMG_8189.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">White marks on 'O' rings</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Anyway, the modern replacements aren't marked in this way, so it seems they have no right or wrong side. That makes it easy.</span></div><div style="text-align: justify;"><div><span style="font-family: arial;"><br /></span></div></div><div style="text-align: justify;"><b style="font-family: arial;">Fitting pipes. </b><span style="font-family: arial;">The correct way to refit a pipe with a flared end is to wipe the pipe and seal with a little hydraulic fluid and then to push the pipe seal onto the pipe leaving 1mm or 2mm of pipe exposed at the end. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5eo_MoyUWiXSqdMDijSgo6OvUQRUN4gWTzPKIaUrk6KNNUDdbBfkwth3-fWt09XJBe7AP0LLO643uxrNIY21hKf8Hf0o36KN38yAp_pdjvW7EH5qIsRl8LoNArRi79iCUqKMrggC-2l9BJtOyEpdZY_tahazzCxJB4EL5gDCT9xxL8nalGowgjA/s724/Pipe%20seal%20diagram%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="353" data-original-width="724" height="195" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5eo_MoyUWiXSqdMDijSgo6OvUQRUN4gWTzPKIaUrk6KNNUDdbBfkwth3-fWt09XJBe7AP0LLO643uxrNIY21hKf8Hf0o36KN38yAp_pdjvW7EH5qIsRl8LoNArRi79iCUqKMrggC-2l9BJtOyEpdZY_tahazzCxJB4EL5gDCT9xxL8nalGowgjA/w400-h195/Pipe%20seal%20diagram%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Fitting hydraulic pipes with seals</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">In some cases the pipe seals sold by different suppliers are different lengths.</span><br /><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb8r1MReBx1o0SCLBux6raACwxAsRyl49PjYBiCeY4OQbV-IJsk7KUxVgRlGttTsRmVEAE_jhB9vMifJs_mUu5dHIKs8zFuMHRsX84NF0gbGl2LdLy_zJMxfWTulBLK_vUFKpDZLHu3-txFLf8bxFJygNBENxW21uLYROuDSMuH5iPIRqSfzGqIg/s4032/IMG_5786.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb8r1MReBx1o0SCLBux6raACwxAsRyl49PjYBiCeY4OQbV-IJsk7KUxVgRlGttTsRmVEAE_jhB9vMifJs_mUu5dHIKs8zFuMHRsX84NF0gbGl2LdLy_zJMxfWTulBLK_vUFKpDZLHu3-txFLf8bxFJygNBENxW21uLYROuDSMuH5iPIRqSfzGqIg/w400-h300/IMG_5786.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Not all pipe seals are made the same</span></td></tr></tbody></table></div><div><span style="font-family: arial;">It's not a lot, but if they are too long, when you try to expose 2mm of pipe at the end, the seal rides up over the flare in the pipe. As you push the pipe in, the seal rides up further. This then prevents you from engaging the flare nut thread in the fitting - increasing the risk of you cross-threading the flare nut. For this reason, the slightly shorter seals are perhaps better as they allow you to have a millimetre or so of pipe end exposed.</span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaVj9RE2uXMzpOycMUxrv1KxGNLXW6HRjsWMtNOaERvbMnso3qoWDsgpZ_27VzWzKjQC-f8Q9Np23X1b2ob70XcwrVaLt6kd26azPa1qo4CK7Hy4LXJiJZnHA-E_3ye68GqOZMAm52TTAj-uAk9B_DOEosxsSsvBt7UF_w2a3zTLytgVLkcM6a3g/s1600/IMG_8208.JPG" style="margin-left: auto; margin-right: auto;"><span style="font-size: x-small;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaVj9RE2uXMzpOycMUxrv1KxGNLXW6HRjsWMtNOaERvbMnso3qoWDsgpZ_27VzWzKjQC-f8Q9Np23X1b2ob70XcwrVaLt6kd26azPa1qo4CK7Hy4LXJiJZnHA-E_3ye68GqOZMAm52TTAj-uAk9B_DOEosxsSsvBt7UF_w2a3zTLytgVLkcM6a3g/w400-h300/IMG_8208.JPG" width="400" /></span></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The seal should fit over the pipe end leaving about 2mm exposed</span></td></tr></tbody></table></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXlyC01qN445U_Q1qaB2X_THnNF8UNtYxSo93nkbb0AOcaO-uVpl-LxmkpDf2Y-u6ACcPHkmJtbzoMjofyYHNWQ5lcf8Ne6G5fpoS35YCWAbkMnjX9Y_z57dBlv4flVRhG7wCL1cbx3xq_D83M-zpEECvBPz_TvMZbkKG44w-b7awzKZtDawsCmw/s1600/IMG_8209.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXlyC01qN445U_Q1qaB2X_THnNF8UNtYxSo93nkbb0AOcaO-uVpl-LxmkpDf2Y-u6ACcPHkmJtbzoMjofyYHNWQ5lcf8Ne6G5fpoS35YCWAbkMnjX9Y_z57dBlv4flVRhG7wCL1cbx3xq_D83M-zpEECvBPz_TvMZbkKG44w-b7awzKZtDawsCmw/w400-h300/IMG_8209.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Fit the pipe with seal onto the receiving end</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The pipe is then pushed squarely into the fitting so that the pipe end engages centrally.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKoJkOKWoEj_oYc056jxmX6q_2UeVu6X5sAcxPmKGyK66HGau3gQmSeG31CQdgrpaGC7wo7SORG0K3DdCe5R7sUhvgucVy6TH8s8UftuzJldSTMeUbKzjDhO_GnwEpaVsiwELBqAm-vw0X_xw9bcgrHGsLKtqbeKlCJRfyXF5vVPtadFd4GCL57g/s1600/IMG_8212.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKoJkOKWoEj_oYc056jxmX6q_2UeVu6X5sAcxPmKGyK66HGau3gQmSeG31CQdgrpaGC7wo7SORG0K3DdCe5R7sUhvgucVy6TH8s8UftuzJldSTMeUbKzjDhO_GnwEpaVsiwELBqAm-vw0X_xw9bcgrHGsLKtqbeKlCJRfyXF5vVPtadFd4GCL57g/w400-h300/IMG_8212.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The pipe end should fit in squarely</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">You should then be able to turn the flare nut a couple of turns by hand before you tighten it.</span></div><div style="text-align: justify;"><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1v4k9aLco-XFHE4VhtqWZAIC89MkqkOgal3yq23xQCMtnrYF5GfFXX72pwa7detzvwlMp7ez9xX6AdNg18RecA9BqiFSqovCDSU8Z_JNVgX4_dqjEgXowLToLuav-hEfoA4A10ELgVO1HtpuSDyNwy8osUih1Ll6c_froGF1nFxDpm219eqnIaw/s1600/IMG_8194.JPG"><img border="0" data-original-height="1200" data-original-width="1600" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1v4k9aLco-XFHE4VhtqWZAIC89MkqkOgal3yq23xQCMtnrYF5GfFXX72pwa7detzvwlMp7ez9xX6AdNg18RecA9BqiFSqovCDSU8Z_JNVgX4_dqjEgXowLToLuav-hEfoA4A10ELgVO1HtpuSDyNwy8osUih1Ll6c_froGF1nFxDpm219eqnIaw/w400-h300/IMG_8194.JPG" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">When you are re-assembling your pipes, there is quite a lot of spring and flex in them: you push the pipe end home in the fitting and it springs out...You need to keep the pipe ends pressed in as you begin to do up the flare nut. </span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><b style="font-family: arial;">Rubber collars for pipe brackets and hoses.</b><span style="font-family: arial;"> You will need these too. To stop vibration and rubbing some pipes have brackets with rubber liners/ collars to cushion the pipes. These rubber collars are often squashed and distorted. For some reason, you can buy the 'cotton reel' type ones (that are only used in a couple of places) but not the 'plain' ones? I reused a lot of the old ones and cut the rims of a couple of cotton reel ones. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Rubber hoses also have collars to stop the tightened Mirex strap or jubilee clip cutting into the hose. You can also buy collars for at least two of the three standard sized hoses. I just re-used all of mine.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Test Fit. </b>I loosely assembled my pipes in their fittings and brackets as I went along. This means you have some 'flex' in the rats nest of pipes as you increasing want to add more. If a pipe won't fit, avoid the temptation to bend or force it. In one case, when I came to thread in a later pipe, I discovered I needed to take a few steps back and undo and remove a pipe I had previously fitted. as it was in the way.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Don't rely on the parts manuals to help you decide which return hose is which. They are for illustration only. In some cases hoses shown as short in the diagram are some of the longest hoses.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Rubbing and Stress. </b>When fitted the pipes should not touch. Gentle rubbing from vibration will soon wear a thin pipe away. And, given Citron hyd</span><span style="font-family: arial;">raulic pressures, it will soon burst. </span><span style="font-family: arial;">If, when you are fitting your pipes, they touch or are tangled, go back and check your photos. Have you routed the pipe correctly? If it has one, is it held properly in it's bracket?</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;"><div style="font-family: -webkit-standard;"><span style="font-family: arial;"><b>Refitting hoses.</b> I assembled most of the hoses off the car. I was re-using original pipes which had hardened slightly. To fit them to their couplings, I softened the ends briefly in a cup of boiling water. I have Ligarex strapping and Mirex buckles so used those.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRVUtRqn4rIfOVEheU-dfW5YSD8lEvSEgbgirAHMm4zKbPYki2ooHxjN-zD8uv2rf-I6mq59ca3AwbZYVTvwE1UP1_1e-iHgJVD1gh0fui2YzdseEPG_Va23k9cYbWjnYeyAJF8ws2I5HrHqbIpicDmbjSvpT_yUEVr9veRxata0FPnvETEQ53_g/s4032/IMG_5745.JPG" style="margin-left: auto; margin-right: auto;"><span style="font-size: x-small;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRVUtRqn4rIfOVEheU-dfW5YSD8lEvSEgbgirAHMm4zKbPYki2ooHxjN-zD8uv2rf-I6mq59ca3AwbZYVTvwE1UP1_1e-iHgJVD1gh0fui2YzdseEPG_Va23k9cYbWjnYeyAJF8ws2I5HrHqbIpicDmbjSvpT_yUEVr9veRxata0FPnvETEQ53_g/w400-h300/IMG_5745.JPG" width="400" /></span></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Reassembling pipes. Note use of computer and reference photos!</span></td></tr></tbody></table></div><div>All I needed to do then, was to re-fit the 'spider' in the middle the cluster to the chassis.....</div><div style="font-family: -webkit-standard;"><span style="font-family: arial;"><br /></span></div></span></div><div style="text-align: justify;"><b style="font-family: arial;">The 'spider'. </b><span style="font-family: arial;">This was my nemesis.......The 'spider' may have three or four legs depending on your car model. It's held to the chassis by a rubber plug that tightens in place with a nut and bolt that causes it to expand.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaW5VH8WyP9MvR91ynCNmrFQxxF2U6Ovqit14RNbOWtBcx4HcYyLE3ziR81YY49Dc10PUpAvEQXE_rXjpCpHFxPWVYu-zjfHXCrEFpSs9G-wO-YjxXQCT9yp2oqentNid4dfbNPdMsEIuDGzbPBUQfmr81Y_lcHXbCQbIDnSCxRysXN9kl4hTy4Q/s3264/IMG_0626.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaW5VH8WyP9MvR91ynCNmrFQxxF2U6Ovqit14RNbOWtBcx4HcYyLE3ziR81YY49Dc10PUpAvEQXE_rXjpCpHFxPWVYu-zjfHXCrEFpSs9G-wO-YjxXQCT9yp2oqentNid4dfbNPdMsEIuDGzbPBUQfmr81Y_lcHXbCQbIDnSCxRysXN9kl4hTy4Q/w300-h400/IMG_0626.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The spider. Lurking.......It nearly had my thumb off.</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">It's comes off and comes apart easily enough.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQ-JXBCFZ6tzh1xdHtWzg3Nr1OPCzD3J0s9dYuEL7nDHEyPo4sVxuO8_bpbvtxb1yGZ4Z6StN9ZIH38GRl5K6ok04I-X4xBxWcWozgpi1gy7Bg_WLF4g-zh9OeZQZ6znvwb1W_BcGe1jwmVrsV5cY2obYX1f8UDSGg3NeTQVMBuCCz7VuQ2O48hg/s4032/IMG_5729.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQ-JXBCFZ6tzh1xdHtWzg3Nr1OPCzD3J0s9dYuEL7nDHEyPo4sVxuO8_bpbvtxb1yGZ4Z6StN9ZIH38GRl5K6ok04I-X4xBxWcWozgpi1gy7Bg_WLF4g-zh9OeZQZ6znvwb1W_BcGe1jwmVrsV5cY2obYX1f8UDSGg3NeTQVMBuCCz7VuQ2O48hg/w400-h300/IMG_5729.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The 'spider' and rubber bung. Spigot '2' has a fluted end?</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">But it's a tight fit to put back on and, several times, tightening it caused it to pop straight back out. It wasn't helped by the fact that the hoses got in the way. In the end I carefully hammered the bung and screw into place using a socket, then carefully added the plastic spider and attached hoses before tightening.</span></div><div style="text-align: justify;"><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;">Three ends on the spider have a bulbous end. The fourth has a fluted end for some reason? Not sure why? </span><span style="font-family: arial;">I don't think it's anything to do with the direction of flow?</span><span style="font-family: arial;"> </span></div></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgANJ4r3lzUgPUaggZJS74-MmKqOj1qKZQ-eAQqwKv4mVSIdQLZA5ZZGBAoIE3cpGgycHZSB8KxnYWd7Q_4_lNy_l1UTrGCfHyjnzCgGJLxBFhPS9NMAeD5HDjV_S3Y35dXHiiB85SdHhza9W-5-4STe0RoOZ74yx1DBUfInO5gpxiv2vnDbUBsfg/s1046/spider.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="664" data-original-width="1046" height="254" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgANJ4r3lzUgPUaggZJS74-MmKqOj1qKZQ-eAQqwKv4mVSIdQLZA5ZZGBAoIE3cpGgycHZSB8KxnYWd7Q_4_lNy_l1UTrGCfHyjnzCgGJLxBFhPS9NMAeD5HDjV_S3Y35dXHiiB85SdHhza9W-5-4STe0RoOZ74yx1DBUfInO5gpxiv2vnDbUBsfg/w400-h254/spider.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The 'spider'. <br />(photo copyright to Citrotech)</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The sharp edge made it very difficult to push the hose on and there was a risk that the spider might snap or crack. It's the hose that comes from a fitting connected to the height corrector in the wheel arch. Having been caught out once before by pipes that have different sized ends (and having cut this particular hose!), I even check the parts book to see if it too, was a special hose. Nope. same size both ends as far as I could tell. Eventually it shoved on.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Final fit. </b>As more pipes and hoses are added, the puzzle got simpler. Once I'd got to a point I was happy with, I went round and methodically tightened all the flare nuts and brackets. This meant giving each pipe end a good shove into it's fitting before I tightened the flare nuts up. I tightened up brackets and checked pipes weren't rubbing.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicI4UOBhSF5U92unx53-o0Rzi3NjqoSFbIpIfjhCJB4UoaZOSVF-jTnZXvabQVao05w325JZV7ANwBIbwx3YZjMvAE5grdRw_qSkv2vT2blrasHkpVcivSi_5zY8VVP55_4ntzSrqnGJhS090pC06ydZvD1bcYgC7BLNwJhXvwXrecp0Nknu8SgQ/s3264/IMG_0112%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicI4UOBhSF5U92unx53-o0Rzi3NjqoSFbIpIfjhCJB4UoaZOSVF-jTnZXvabQVao05w325JZV7ANwBIbwx3YZjMvAE5grdRw_qSkv2vT2blrasHkpVcivSi_5zY8VVP55_4ntzSrqnGJhS090pC06ydZvD1bcYgC7BLNwJhXvwXrecp0Nknu8SgQ/w400-h300/IMG_0112%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">A 'before' shot and..........</span></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioC8hYv9ib2_540w1ipPq_zTnDaWuh9Uh8DEsHyuHidmksdntEfTEq7G2c6wQ23oig1shPy5Bl5kI1kpTOh3bPjm3mKWoZybTjWinPz2AFa0KHX0RTahCLkarFSLE-3AFP8bwBuZkGlF5w5kAOkwu398wQYP1GAv4IUsVkrQXpA0D_ryn2StyWWw/s4032/IMG_5766%20copy.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioC8hYv9ib2_540w1ipPq_zTnDaWuh9Uh8DEsHyuHidmksdntEfTEq7G2c6wQ23oig1shPy5Bl5kI1kpTOh3bPjm3mKWoZybTjWinPz2AFa0KHX0RTahCLkarFSLE-3AFP8bwBuZkGlF5w5kAOkwu398wQYP1GAv4IUsVkrQXpA0D_ryn2StyWWw/w400-h300/IMG_5766%20copy.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">.....the gratuitous 'after' shot</td></tr></tbody></table></div><div style="text-align: justify;"><b style="font-family: arial;">To 'yellow' or not to 'yellow'? </b><span style="font-family: arial;">There are a lot of fittings to tighten and I was still leaving some loose until the suspension and engine were added. This being so (and despite telling myself I wouldn't) I marked all those I'd tightened with a blob of yellow paint..... I can see why Citroen did it. Someone has suggested that it was the quality control team at the factory that that did this, but it's always the same parts with marks. I'd have though it was up to the assembly line workers to do these up right in the first place?</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqw-uNhapxbGq1Bo4j_5EzubnXnRLnBD87NvoQS-74lmKWtvZRmuzb_k4aUVL_AxzC8LvOmr5LzUOef6OI4plnbuxNXkVK48nodwaI3mJFs1LJy-HJsW79RGwE8_jfzT-zLUwYuc2fvF4KAlz9QvzWxwTEuCMcO3w0gu1snYjh0hz8GMzPaZ8mxA/s4032/IMG_5789.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqw-uNhapxbGq1Bo4j_5EzubnXnRLnBD87NvoQS-74lmKWtvZRmuzb_k4aUVL_AxzC8LvOmr5LzUOef6OI4plnbuxNXkVK48nodwaI3mJFs1LJy-HJsW79RGwE8_jfzT-zLUwYuc2fvF4KAlz9QvzWxwTEuCMcO3w0gu1snYjh0hz8GMzPaZ8mxA/w400-h300/IMG_5789.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">A splash of yellow</span></td></tr></tbody></table></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEib_TbV9H-XDdJ1YWrGw3_zOl_tJy2nlu-x7lmSxUPnYS53X5B3E3NzizOOR3aJJbkwUgSxNLCFim69dLfrZ89NYATrvjpG7sNui_V3sDBbX0jL6ZLpWP9ng0OpQmCeq_iar--DpR9gH7EpcCcnoFTqZHttxfoz9eWu3hamykmW__wrWO5_qWkdMg/s4032/IMG_5790.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEib_TbV9H-XDdJ1YWrGw3_zOl_tJy2nlu-x7lmSxUPnYS53X5B3E3NzizOOR3aJJbkwUgSxNLCFim69dLfrZ89NYATrvjpG7sNui_V3sDBbX0jL6ZLpWP9ng0OpQmCeq_iar--DpR9gH7EpcCcnoFTqZHttxfoz9eWu3hamykmW__wrWO5_qWkdMg/w400-h300/IMG_5790.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">And a splash more</span></td></tr></tbody></table><div style="text-align: justify;"><span style="font-family: arial;">I'd also started doing this on all the main nuts and bolts I'd tightened elsewhere - again following Citroen's lead.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Making Sense Of It All.</b> There is an inevitable motorway of pipes and hoses making their way toward where the reservoir would be on the left side of the car.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgavYQIIU-yE1cotVG-fBms-eWsrijwdO1-lcZtN_aUIHkphXSbhmGBRMi9Yn2nKETUjLKNs06R2atw010OTM9U5LXhDBth3ixG8OWGj15zRSm5SPKos2M-O5W8u-PmhnrG4kic-PPgO8tyXVg-Nc8KxkQMbL_qDfjYEgiyo9uG7HccYYVTj4wb2A/s3264/IMG_0606.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgavYQIIU-yE1cotVG-fBms-eWsrijwdO1-lcZtN_aUIHkphXSbhmGBRMi9Yn2nKETUjLKNs06R2atw010OTM9U5LXhDBth3ixG8OWGj15zRSm5SPKos2M-O5W8u-PmhnrG4kic-PPgO8tyXVg-Nc8KxkQMbL_qDfjYEgiyo9uG7HccYYVTj4wb2A/w400-h300/IMG_0606.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Motorway</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I haven't finished fitting everything yet, but I have done several trial fits to make sure that everything is accounted for and that nothing is twisted, snagged or pinched. </span></div><div style="text-align: justify;"><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0FoqN9FgcqxX2_NFA1eklYrf0o9yUh1X5jfCFBMFf48diPHsZquEMBKUaN4yO8rANTheK8eQJWqqf8BXc3OxJt6ARjKQqaHZqT1Bi_ZLsVSBKY44tfJjgdfpN78MhZ5vJys9mQeqAlQhQsQDcZq9RpZYMU-NBj8Bikq4w9iYugZnmXeYXLF4DZQ/s4032/IMG_5753.JPG"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0FoqN9FgcqxX2_NFA1eklYrf0o9yUh1X5jfCFBMFf48diPHsZquEMBKUaN4yO8rANTheK8eQJWqqf8BXc3OxJt6ARjKQqaHZqT1Bi_ZLsVSBKY44tfJjgdfpN78MhZ5vJys9mQeqAlQhQsQDcZq9RpZYMU-NBj8Bikq4w9iYugZnmXeYXLF4DZQ/w400-h300/IMG_5753.JPG" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">I'm going to rebuild the 'gear brain' and so will have some pipes to fit when that goes back on. I will probably fit the reservoir and connect everything to the bottom before the engine goes back in. There are also a couple more brake pipes to fit across the gearbox after the engine is fitted.</span></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com2tag:blogger.com,1999:blog-4597517440111518822.post-37228261787753992382022-10-29T07:44:00.006+00:002022-10-30T08:40:30.080+00:00Schoolboy Error.....The 32cm Solution<div><div style="text-align: justify;"><span style="font-family: arial;">Sometimes you take the lazy way. And really wish you hadn't.</span></div><span style="font-family: arial;"><div style="text-align: justify;"><br /></div></span><span style="font-family: arial;"><div style="text-align: justify;">As part of the process of repainting the engine bay (you can read about that <a href="https://ds-restoration.blogspot.com/2022/08/painting-engine-bay.html" target="_blank">HERE</a>) I needed to remove the metal hydraulic return pipes from the 'tunnel' under the engine bay. This is two pieces joined by a short 10cm section of LHM hose. Everything was covered in grit and grease and dirt and space was cramped under the car. </div></span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNCpihSiBHIybD4dOrxjWoDuEjYNG0hEI3Jo3WuSwBvfS-Y7bF1leec2oQ_sURL2zlIaPGCuaWxWXwoP1qq8_k86OSQJ8Y3JtpjpJUIKboiPiPsxSL07x9pIK1iqCfOo9zv21LQY07Kfh6JkicTr0yUZLDnbHdbJcn_sV2T0SPCY0QrmxNTqH0Uw/s4032/IMG_4427.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNCpihSiBHIybD4dOrxjWoDuEjYNG0hEI3Jo3WuSwBvfS-Y7bF1leec2oQ_sURL2zlIaPGCuaWxWXwoP1qq8_k86OSQJ8Y3JtpjpJUIKboiPiPsxSL07x9pIK1iqCfOo9zv21LQY07Kfh6JkicTr0yUZLDnbHdbJcn_sV2T0SPCY0QrmxNTqH0Uw/w400-h300/IMG_4427.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Return pipe join under the engine bay</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="font-family: arial;">I wrestled with the two Ligarex buckles and belts and got those off. </span>But then couldn't get my hands into the narrow tunnel and around the pipe ends to pull them free from the old and hardened rubber hose. </span><span style="font-family: arial;">Although all parts have specific part numbers, (this one was 'DXN 394-147') a quick inspection convinced me that the hose was just common hosing. </span><span style="font-family: arial;">You probably know the kind of thing: it has a green stripe and three ribs along it. It was just</span><span style="font-family: arial;"> a simple Citroen solution to a simple assembly problem</span><span style="font-family: arial;">. I thought once about it (but not twice): i</span><span style="font-family: arial;">t could be replaced with a short section of standard replacement LHM hose. </span><span style="font-family: arial;">Out came the Stanley knife and I cut the hose in two......What harm could it do? Job done. All pipes removed.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I checked the hose I'd cut. </span><span style="font-family: arial;">Yep - standard LHM hose with a 14mm outer diameter and a 7mm internal </span><span style="font-family: arial;">diameter.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjw8HzLqfujedvDyNMEPLQHr7p5ydCw-I3gkYZBT4C5cNBgmyYs1ngc-uoMTqoeNM-1Tme7wRYl7HCFAvkw4BlDgaydhloBtsrxiNwJk-MFDG4d8JhwpvyQJHJuxwHWpT6bf7yhruc_oIWkbizqW8HMAqOSgXtANEZNjQ99aICQqbDGI4AWBSLCPw/s4032/IMG_5705.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjw8HzLqfujedvDyNMEPLQHr7p5ydCw-I3gkYZBT4C5cNBgmyYs1ngc-uoMTqoeNM-1Tme7wRYl7HCFAvkw4BlDgaydhloBtsrxiNwJk-MFDG4d8JhwpvyQJHJuxwHWpT6bf7yhruc_oIWkbizqW8HMAqOSgXtANEZNjQ99aICQqbDGI4AWBSLCPw/w400-h300/IMG_5705.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">10cm of trouble (to come)</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">No problem. Easy to replace. I'd just need to order some......</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">Fast forward couple of months </span><span style="font-family: arial;">and I was at the point of putting all the other pipework back. All the other pipe and hose work had been removed and sat in a pile. Needing a 'donor' piece of LHM pipe in a hurry, I found a pipe with a short (24cm) length of 14 x 7 LHM hose. This piece.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_cgVjtwPcof8fqyuVet2pr97yQnUnNWoaAcxv2QBX4FFf_LZsaVkUOdQx3_b-oIHBDGh5pYS5afAl4Q-AaepPOA432t_S3JznRqOip3DjkW3c0M7AdKK22_b6agGRlN98YNI-SB50pNaRlfSFoQk3qoDgsRr8H8AvheIYYx1XVNrI-K-xrvYdYA/s2998/IMG_4246.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2177" data-original-width="2998" height="290" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_cgVjtwPcof8fqyuVet2pr97yQnUnNWoaAcxv2QBX4FFf_LZsaVkUOdQx3_b-oIHBDGh5pYS5afAl4Q-AaepPOA432t_S3JznRqOip3DjkW3c0M7AdKK22_b6agGRlN98YNI-SB50pNaRlfSFoQk3qoDgsRr8H8AvheIYYx1XVNrI-K-xrvYdYA/w400-h290/IMG_4246.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">My first 'donor' hose</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I cut myself 10cm, leaving 14cm. Job done. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOEirExw58Nu-DAm5YPvrJtHZOwMyWaaQjlTHzrmG2hn6f6lcwmPRd1_U_J3PlCixvUJDiMMncNeqnHrOTV5QJP1F6PXRwmKIMOtFztDn8sLtLu99Sj73KioZF-2IYKiR-io4yDX_9b7arjyioSOske_hLYsMXG8_ussXa0Ci0zetrD_2_aCJIzg/s4032/IMG_5422.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOEirExw58Nu-DAm5YPvrJtHZOwMyWaaQjlTHzrmG2hn6f6lcwmPRd1_U_J3PlCixvUJDiMMncNeqnHrOTV5QJP1F6PXRwmKIMOtFztDn8sLtLu99Sj73KioZF-2IYKiR-io4yDX_9b7arjyioSOske_hLYsMXG8_ussXa0Ci0zetrD_2_aCJIzg/w400-h300/IMG_5422.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">New pipe join fitted</span></td></tr></tbody></table><span style="font-family: arial;">No problem. Easy to replace. I'd just need to get round to ordering some......</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">Fast forward to last weekend. I was gradually putting all that other pipework back. One of the first things I needed was that pipe that had the 24cm length of hose on it. </span><span style="font-family: arial;">Damn! It was now cut down to 14cm! </span><span style="font-family: arial;">I looked at all my pipework and found <i>another</i> group of hoses of the right diameter, connected to a 'T' joint. It had several branches. Planning ahead, so that I didn't need to buy too much replacement hose, I picked on the shortest branch (32cm long this time!) to be my donor. Here it is.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmodCwmMxloxS4Zf-4lm5QY24PDyYj1mUUtswikq4VSgO4-rp81p0DywNWDfwOaRJD6kBChUTiZ314WP_bS9SiF8QeY0XlWTbpwpHafsr9_EUrFcorM6tOV_vQMyFCrs8ezY_NEAyhw402iDgfJ0FMVjJAa49kWfTA-xqIq_nTojpD6WXzHEnOLA/s4032/IMG_5667.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmodCwmMxloxS4Zf-4lm5QY24PDyYj1mUUtswikq4VSgO4-rp81p0DywNWDfwOaRJD6kBChUTiZ314WP_bS9SiF8QeY0XlWTbpwpHafsr9_EUrFcorM6tOV_vQMyFCrs8ezY_NEAyhw402iDgfJ0FMVjJAa49kWfTA-xqIq_nTojpD6WXzHEnOLA/w300-h400/IMG_5667.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">My second 'donor' hose......</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I removed the hose. I noticed it was fatter at the end that fitted to the 'T' piece. But that was alright - I only needed 24cm of it and so wouldn't need to use that fat end. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHjLJfMNc9TPYwAs7xjqIIpJSu1pBxfc03QbdEfy0SRqoLbTjG8q71-RzvldT7Tg5LLzzNuk-uaDu2gQWnv7MZuMD-eTSw2Gobeqdku2oV8jL-oIiySmiWdvvge7q8Flc64dHjI4Ii7xCpPj2RBXnrhu8SUxRgd7KO1xdejI4TsfWiaRiA-HyGfA/s4032/IMG_5669.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHjLJfMNc9TPYwAs7xjqIIpJSu1pBxfc03QbdEfy0SRqoLbTjG8q71-RzvldT7Tg5LLzzNuk-uaDu2gQWnv7MZuMD-eTSw2Gobeqdku2oV8jL-oIiySmiWdvvge7q8Flc64dHjI4Ii7xCpPj2RBXnrhu8SUxRgd7KO1xdejI4TsfWiaRiA-HyGfA/w300-h400/IMG_5669.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Fatter at one end.....</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Without thinking much (enough!) about it, I cut 24cm off the end and used it get on with my plumbing job. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhogopQZVWuZEkOp4uTVYKeaKd5EkMonmbfmhIZerSWoKFzg43moMr-B8bxiIJYyyjVb-nivOupUIsxOjrEpyh21YSx7R-0GnmNXN1R1EON5dJkMgwx3QuPiuWpaxLJLpbnUwqWjbJBkhM7176BItYPZuBK6wohzG7nlxmCVtKaPgqJlqtavOfP0w/s4032/IMG_5682.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhogopQZVWuZEkOp4uTVYKeaKd5EkMonmbfmhIZerSWoKFzg43moMr-B8bxiIJYyyjVb-nivOupUIsxOjrEpyh21YSx7R-0GnmNXN1R1EON5dJkMgwx3QuPiuWpaxLJLpbnUwqWjbJBkhM7176BItYPZuBK6wohzG7nlxmCVtKaPgqJlqtavOfP0w/w300-h400/IMG_5682.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Good progress on the pipework</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Satisfied with progress, I chuckled to myself, thinking how the need for 10cm of hose had now grown to a need for 32cm of hose.....Still, n</span><span style="font-family: arial;">o problem. Easy to replace. I'd just need to pull my finger out and order some......It probably comes in minimum lengths of 1 metre anyway. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">But something was niggling me. It wasn't the bit I'd cut off and used - but the bit that was left. I went back and looked more carefully at the remaining 8cm piece form the 'T' junction and was suddenly struck by a sickening discovery. The hose end wasn't just fatter where it had been squeezed over the 'T' junction. It was fatter for more of the length of the hose. Almost as if it was moulded that way......</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEif-YyQrDQx7NyVZlxz_eiXvfhSu5l-Hji3HoVH44pgc-x0FW6EJbWi6_6Wgb3S6VOx0eLMJZ8CWK0ceUFKZOJ3HXiK7mwvLnYeudJJcU5Edrt5FaKDkdTIW_hWw0LgxNbewKc36rwhJv_1guLS8Hlkwr_3R8Ze1rMkEOtSiH4KUnUjvhT111fq2w/s4032/IMG_5706.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEif-YyQrDQx7NyVZlxz_eiXvfhSu5l-Hji3HoVH44pgc-x0FW6EJbWi6_6Wgb3S6VOx0eLMJZ8CWK0ceUFKZOJ3HXiK7mwvLnYeudJJcU5Edrt5FaKDkdTIW_hWw0LgxNbewKc36rwhJv_1guLS8Hlkwr_3R8Ze1rMkEOtSiH4KUnUjvhT111fq2w/w400-h300/IMG_5706.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">8cm of trouble</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Surely it wasn't a special part was it? I grabbed a parts manual and started </span><span style="font-family: arial;">thumbing through. </span><span style="font-family: arial;">Oh dear. The part was indeed 'special'. </span><span style="font-family: arial;">It's size was given as '7-10' which I very quickly translated as 7mm inner diameter at one end, but changing to 10mm inner diameter at the other.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYcKAO9aMNU0CbdUD7S2IUBjf32rCtbr4lES5ZOBDdpxSI9vXxBRjlra3WjK1sGQnSivaw8CIlDbdUYmbGZyhKWm1KGBDnfq7VQl0kG4Fgu2A5f0_z_Y8rLApxMztMTRuq-kt9eNJQY2JCULzbX4Y7v_FYaw1u23-YRECdBelF5SWhC8etnERfuQ/s1391/DXN%20394_74.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="135" data-original-width="1391" height="62" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYcKAO9aMNU0CbdUD7S2IUBjf32rCtbr4lES5ZOBDdpxSI9vXxBRjlra3WjK1sGQnSivaw8CIlDbdUYmbGZyhKWm1KGBDnfq7VQl0kG4Fgu2A5f0_z_Y8rLApxMztMTRuq-kt9eNJQY2JCULzbX4Y7v_FYaw1u23-YRECdBelF5SWhC8etnERfuQ/w640-h62/DXN%20394_74.jpeg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Part 8: internal diameter 7mm (going to) 10mm......</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Examining the plastic 'T' piece, it suddenly looked enormous. </span><span style="font-family: arial;">Why manufacture a 'T' join with a 10mm end for 7mm hose? Something to do with creating pressure for the return flow perhaps? It got better: a</span><span style="font-family: arial;">s well as being 10mm diameter, each branch also had a bulbous end making it 13mm diameter! </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitHbdFcmJLY1y6y1f3gnQxfK_WlrU6x5XXqaY_--5BNipOR5ukhu2Pbo_0zLVoEaxuS8QuPFlyZ1GKfbnuXUJNKYLIAw-pUSXb_1HdbWvfeIi8FKJdt2Za-2wsnhNQdOJ4RDbILTxFtQI8of4I_BGGzMe6FVNJRRry-BAR8Dp4eG_XqQgNL74uWw/s4032/IMG_5730.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitHbdFcmJLY1y6y1f3gnQxfK_WlrU6x5XXqaY_--5BNipOR5ukhu2Pbo_0zLVoEaxuS8QuPFlyZ1GKfbnuXUJNKYLIAw-pUSXb_1HdbWvfeIi8FKJdt2Za-2wsnhNQdOJ4RDbILTxFtQI8of4I_BGGzMe6FVNJRRry-BAR8Dp4eG_XqQgNL74uWw/w400-h300/IMG_5730.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">My nemesis</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Other people do wholesale replacements of LHM hose as part of full restorations. Some must have navigated this problem before (or never noticed it?). </span><span style="font-family: arial;">I would expect that putting the end of standard 7mm size hose in boiling water would soften it enough to go over the 'T' piece nozzle, but I had no confidence that modern rubber hose would not begin to split once it had cooled down. That was not my 'Plan A', but might need to be my 'Plan B'..........(Plan C was to try and use a four-way 'spider' connector).</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">Sure - taking 24cm as a donor hose hadn't been a problem, but finding a replacement 32cm hose with two different sized ends just might be! </span><span style="font-family: arial;">Bugger! What started out as a simple and easily met need for a 10cm length of generic hose had rapidly turned into a global search for a very specific piece of specialist 32cm long hose. It was the kind of thing 'Citrotech' might re-manufacture, but I never got that far. </span><span style="font-family: arial;">Some bad-tempered Googling turned up one genuine Citroen part in the USA........</span></div><div style="text-align: justify;"><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoIrp-2UjAdpmNyuHxNAGoZkHi9Z6AfA22UoczrMFdwgqbWHMoGat1t73zLF0HgCAnMmuvYi92HvVe0iwE5hgskgnHAXFORBbRv8YtrwoI6Uf50arHl8c51-uNoJRNknd6pW1EnlAnIoEKR250j_U4M_DyljtnRS0c0SPRz90e5GWeOhXF2yHBtA/s1420/USA.jpeg"><img border="0" data-original-height="800" data-original-width="1420" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoIrp-2UjAdpmNyuHxNAGoZkHi9Z6AfA22UoczrMFdwgqbWHMoGat1t73zLF0HgCAnMmuvYi92HvVe0iwE5hgskgnHAXFORBbRv8YtrwoI6Uf50arHl8c51-uNoJRNknd6pW1EnlAnIoEKR250j_U4M_DyljtnRS0c0SPRz90e5GWeOhXF2yHBtA/w400-h225/USA.jpeg" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">.......and one in Europe</span></div><div style="text-align: justify;"><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZnDGu9LOgoHxsD_GoXSY56EsDXNdWUsTsOkaSgmwQFiUqjsYxabbyb7Cr5otLGWtzugz47LGHg-H5wdn-_eH4efAhNxulKjr0TFFU3eqFu_pw-K0U9kOXVyN4Xo3ayh-qDMBitWkwDDAmlE7KnV0JwJB7Wgl-ER6SzgAQRQUvP8TfxILTNJZenw/s1342/andre.jpeg"><img border="0" data-original-height="827" data-original-width="1342" height="246" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZnDGu9LOgoHxsD_GoXSY56EsDXNdWUsTsOkaSgmwQFiUqjsYxabbyb7Cr5otLGWtzugz47LGHg-H5wdn-_eH4efAhNxulKjr0TFFU3eqFu_pw-K0U9kOXVyN4Xo3ayh-qDMBitWkwDDAmlE7KnV0JwJB7Wgl-ER6SzgAQRQUvP8TfxILTNJZenw/w400-h246/andre.jpeg" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">I also investigated 'Plan B' - the cost of generic replacement hose. It was indeed sold by the metre. At £19 per. Plus there was postage on top of course. The Ebay USA part looked to be a good buy, but postage was high for just a small hose that could fit in a Jiffy bag and I'd been stung by unexpected American import duties (and added Duty collection fees!) before.</span><span style="font-family: arial;"> </span><span style="font-family: arial;">All things considered, I bought from Citroen Andre. It wasn't a hard decision as I've bought there before. I also used it as the excuse to buy something else I'd had my eye on, to justify the cost of delivery. </span><span style="font-family: arial;">So I got away with it. Next time it might not be so easy to find an original part. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">As a bonus, the parts arrived very quickly. Less than a week between order and delivery and here for the coming weekend. </span><span style="font-family: arial;">And here it is: the expensive 32cm solution to a quick and easy 10cm problem.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEin5xg4QRdAaUCMus62Gwv89qGSMpragaYr1NSm0iOmx5EsxIXzTZ8nYHCtIKl6xYOLSyomsP9dLXjXsJ-MrcMKAKiDAX9IoEycTHlqX3Qh5MnTt6i1OwQ58JWGHDvzH5bHYgvlMRFOTxPCOh1CoJfVf3uSkxL98dfrPNQbu0-qcSDtGCbJTQ3ofA/s4032/IMG_5701.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEin5xg4QRdAaUCMus62Gwv89qGSMpragaYr1NSm0iOmx5EsxIXzTZ8nYHCtIKl6xYOLSyomsP9dLXjXsJ-MrcMKAKiDAX9IoEycTHlqX3Qh5MnTt6i1OwQ58JWGHDvzH5bHYgvlMRFOTxPCOh1CoJfVf3uSkxL98dfrPNQbu0-qcSDtGCbJTQ3ofA/w400-h300/IMG_5701.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Lucky Find!</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">You can see quite clearly that the diameter of the hose changes towards the left and 10mm hole end. </span><span style="font-family: arial;">And of course the two different sized plugs in the end are a dead give away!</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFMYZhmfrqVDgHqdQamEB9nRLjYqLFbK4R3QI7XhIscCf2_f9cppHC1M6gT4bG-tCX-BCKadRVz1TApmvGeRF9V8D55vtwI9PYaB9zgLx6JofvUTXVgprIcMmBpUe-rmwLbCXPKK3sKaJA0CvHPpXUjwq3DP5K2sqpMjHbCVNMurhnaPT7gGhpMA/s4032/IMG_5707.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFMYZhmfrqVDgHqdQamEB9nRLjYqLFbK4R3QI7XhIscCf2_f9cppHC1M6gT4bG-tCX-BCKadRVz1TApmvGeRF9V8D55vtwI9PYaB9zgLx6JofvUTXVgprIcMmBpUe-rmwLbCXPKK3sKaJA0CvHPpXUjwq3DP5K2sqpMjHbCVNMurhnaPT7gGhpMA/w400-h300/IMG_5707.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">All smiles now</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">It's just curiosity, but I may need to get a Vernier out and take some measurements as the difference in diameter seems to be more than 3mm. I can't see standard 7mm hose fitting over that very easily.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4p5_iPgciw7DJgoLasFTW3wBNVbOxtu45SuN3s74bnX8lUewPPK8DqxnNm8EdaMMVscju0I_5ertdI16tu8dvBDfOFnNPZ8UM0_YC4jIrgLQJmWq9t7xDJ9yP7r-V3S9BcTxl2j305D3PkS5VRH-cW2X4XJnAnXQa-dlyQ1CXuuMJW8SJysQlUg/s4032/IMG_5708.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4p5_iPgciw7DJgoLasFTW3wBNVbOxtu45SuN3s74bnX8lUewPPK8DqxnNm8EdaMMVscju0I_5ertdI16tu8dvBDfOFnNPZ8UM0_YC4jIrgLQJmWq9t7xDJ9yP7r-V3S9BcTxl2j305D3PkS5VRH-cW2X4XJnAnXQa-dlyQ1CXuuMJW8SJysQlUg/w400-h300/IMG_5708.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Well of course it's obvious now......</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I'm expecting to fit the new part, and other pipes and hoses, this weekend. I just need to avoid the temptation to 'borrow' anything else.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">Whats have I learned? Probably: </span><i style="font-family: arial;">"If it sounds like a bad idea - it probably is!"</i></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-80780110857266481592022-10-01T16:18:00.004+00:002023-05-24T20:33:26.566+00:00Height Corrector - Stripdown and Overhaul<div style="text-align: justify;"><span style="font-family: arial;">Before I can put the engine back in, I need to replace the hydraulic piping. And if I'm going to do that, I might as well take the opportunity to rebuild the front height corrector.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiW4Ev7wfqhZn6jUpTehCZa9V7ZUjzXuS0brDTdjlJNklNzYSgu7JZmXfyRyCvQ4uVNtloAqx6pmm0kMwWixCbzIygQEW0sTXuloJu4HZOid2L4OiBFIJI_ABQclDl0nrNmd-FcxzaRKjTCOBPXEgi_yp0-jE7liRk8N20WA_kKPM19JCyUy9Gqhg/s4032/IMG_5607.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiW4Ev7wfqhZn6jUpTehCZa9V7ZUjzXuS0brDTdjlJNklNzYSgu7JZmXfyRyCvQ4uVNtloAqx6pmm0kMwWixCbzIygQEW0sTXuloJu4HZOid2L4OiBFIJI_ABQclDl0nrNmd-FcxzaRKjTCOBPXEgi_yp0-jE7liRk8N20WA_kKPM19JCyUy9Gqhg/w400-h300/IMG_5607.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">A DS height corrector</span></span><br /></td></tr></tbody></table><span style="font-family: arial;">The purpose of the height correctors (there is also one at the back of the car) is to maintain a given road height under any static load. 'Static' is important, as the height correctors play no role (in the correction of height) when the car is travelling at speed over bumps - the movements are too brief for the height corrector to react and operate.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>How It Works</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">The height corrector consists of a slide valve which opens or closes hydraulic inlet/ outlet ports to allow fluid to flow to the suspension circuit or to be released back to the reservoir.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh16usTnceXVINhSY_UP6HHF4Bh8sDeNux1XCYm8zLnZmR1pwlWNezTv5UQ9fthehEPiDrQSOqkUmSE85c7RqXYDOZ4w6vZcZkC5bVoW8xJf3XQfRi4xotX8D_ObdkyBjh3x-FerVugw8uvhUexURKI3dxXLicWmshohxZ0H8g_BzookpQ10wabHA/s865/main%20function.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="779" data-original-width="865" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh16usTnceXVINhSY_UP6HHF4Bh8sDeNux1XCYm8zLnZmR1pwlWNezTv5UQ9fthehEPiDrQSOqkUmSE85c7RqXYDOZ4w6vZcZkC5bVoW8xJf3XQfRi4xotX8D_ObdkyBjh3x-FerVugw8uvhUexURKI3dxXLicWmshohxZ0H8g_BzookpQ10wabHA/w400-h360/main%20function.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Operation of the slide valve in the hight crrector</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">A control rod is connected between the anti-roll bar and the ball joint on the end of the slide valve in the height corrector. It's set up so that, at normal ride height, the slide valve is in it's central position. </span><span style="font-family: arial;">If a load is added to the car (passengers gearing in for example), the car sinks and the anti-roll bar twists, casing the rod to the height corrector to move the slide valve. This opens the inlet port to the suspension circuit causing the car to rise. This causes the anti-roll bar to move again...... which in turn acts on the slide valve in the height corrector causing it to move <u>back </u>until it reaches it's central position and once again blocks fluid to the circuit.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh27_PXIuqkcp1XSQzfLiIyp1R8bhRoy_Ps6ZW2YvVQjr7WEJQ1C-ZoedqwtbLZ7-NKijMhCgZbSX78oo0POyu04RawB20eQHN1_l1og3lJqmuxRaDHyjG0aLoMs6E0FJDe5xx-BNi3ra65cq8N4z6-Mh6-ocrQ3a1LbBb8ziehZghmkPmq5n6uAQ/s1275/anti%20roll.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="404" data-original-width="1275" height="126" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh27_PXIuqkcp1XSQzfLiIyp1R8bhRoy_Ps6ZW2YvVQjr7WEJQ1C-ZoedqwtbLZ7-NKijMhCgZbSX78oo0POyu04RawB20eQHN1_l1og3lJqmuxRaDHyjG0aLoMs6E0FJDe5xx-BNi3ra65cq8N4z6-Mh6-ocrQ3a1LbBb8ziehZghmkPmq5n6uAQ/w400-h126/anti%20roll.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The anti-roll bar is connected to the front height corrector</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">That's it's main function but, to accomplish this in a satisfactory way, it also consists of two disc valves which control the flow of a body of fluid between the two halves of the height corrector and which serve to dampen the action. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVBS_HX_W_ILDx-7CJEwOsJWH5ZqpmdtbDgOQS7Ct5xbhfCVpILlcASMmtN7TY5dZQy_lKEpdTqPsEYQ4qWOGwbHeGzWLwo3D8I9avit__w_e5zQJOE_IooItV0TtPNRr6goc18CDay5Jylv8J2iAC-xgq6lCCdzPcNRHH3i7WwrAZOzN_yRgQ9w/s1070/routes.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="567" data-original-width="1070" height="213" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVBS_HX_W_ILDx-7CJEwOsJWH5ZqpmdtbDgOQS7Ct5xbhfCVpILlcASMmtN7TY5dZQy_lKEpdTqPsEYQ4qWOGwbHeGzWLwo3D8I9avit__w_e5zQJOE_IooItV0TtPNRr6goc18CDay5Jylv8J2iAC-xgq6lCCdzPcNRHH3i7WwrAZOzN_yRgQ9w/w400-h213/routes.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Disc valves (in red) on the slide valve</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The ends of the slide valve are connected to rubber diaphragms and the movement of the valve causes - and is dependent upon - the movement of fluid from one half of the connector to the other. </span><span style="font-family: arial;">The flow of this fluid governs the rate at which the slide valve is able to move - (and so the rate at which the car corrects its height). There is an 'easy route' and a 'hard route' between the two halves of the height corrector. The 'hard route' is via a dash pot which restricts the flow of fluid and so slows the movement of the the slide valve. </span><span style="font-family: arial;">Access to either of these routes depends on which disc valve is open or closed.</span><span style="font-family: arial;"> And THAT is determined by which direction the valve is moving in......</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCyTK5D1m40KCHhQt-odO5H0Urb9iNO2ydFu3behazRo27o5KKyRGLN5OfCc9ibhmPGzAN-R9Pl0DoYLMEuNCriuMm_4pJf96KImPobd32ea3Sq-Q_HVd24y9ZmGTBjRQofXrQsd0cmXehuMBrqZkbEtKOirkWrB6DcK_UBFR2LE9ZnEhhOvwNbQ/s4032/IMG_5348%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCyTK5D1m40KCHhQt-odO5H0Urb9iNO2ydFu3behazRo27o5KKyRGLN5OfCc9ibhmPGzAN-R9Pl0DoYLMEuNCriuMm_4pJf96KImPobd32ea3Sq-Q_HVd24y9ZmGTBjRQofXrQsd0cmXehuMBrqZkbEtKOirkWrB6DcK_UBFR2LE9ZnEhhOvwNbQ/w400-h300/IMG_5348%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Anatomy of a height corrector.....</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The disc valves are on the slide valve and, when it's in it's central position, they are normally held closed by weak springs. Shoulders on the slide valve open one or other disc valve as the slide valve moves. </span><span style="font-family: arial;">The slide valve being caused to move </span><u style="font-family: arial;">away</u><span style="font-family: arial;"> from the central 'normal' position leaves the 'clear' route closed. Fluid is forced to move through the restricted 'dash pot' route and the initial change is gradual/ resisted. Example: when passengers get in the car, the car initially and visibly sinks fairly slowly - resisting the change. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUJv6zZEq3p2AHlTbttUKgaG1RC1kGdFJc0CWm8qDoaUtV3hQgohoewcxmUB3fGDVJSvIopOz5JGZ9XVTX-p5iktbSHfiACe_Zu8VTa8ovDXhzujN2JeWNU_kRpbv-kXiKJng71BPYSmkB_3Y8Q2jN8oLIza9di7o1kWbeV2lQJsVxVhtXtCgfdg/s700/passengers%20in.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="637" data-original-width="700" height="364" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUJv6zZEq3p2AHlTbttUKgaG1RC1kGdFJc0CWm8qDoaUtV3hQgohoewcxmUB3fGDVJSvIopOz5JGZ9XVTX-p5iktbSHfiACe_Zu8VTa8ovDXhzujN2JeWNU_kRpbv-kXiKJng71BPYSmkB_3Y8Q2jN8oLIza9di7o1kWbeV2lQJsVxVhtXtCgfdg/w400-h364/passengers%20in.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Moving away from centre: the disc valves leaves the 'clear passage' closed (circled in yellow). <br />Note the movement of the diaphragms too.</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The slide valve being caused to move </span><u style="font-family: arial;">back</u><span style="font-family: arial;"> to the central position begins with the 'clear' route held open. Fluid is able to move more freely from one side of the body to the other, and so stabilisation, is more rapid. Example, once the passengers are in the car it quickly rises back to it's original height.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiKi3SsYkNUp3zPFPvYGdvV1deDmYH1lW8LGHwZaq8LWP_K21s6wijxcsCIfRhn3aIs50wheLI4qC20p8s56skSH5y2BHMeiOoaVHTM4Ub73d4xBinVkItxWJdsq62T8kUhYwiHlxkTL4H3A6yNNrXOgJDOWy-ATs6Ul7QRmh9tCIZfFxX7_2USA/s665/back%20to%20normal.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="648" data-original-width="665" height="390" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiKi3SsYkNUp3zPFPvYGdvV1deDmYH1lW8LGHwZaq8LWP_K21s6wijxcsCIfRhn3aIs50wheLI4qC20p8s56skSH5y2BHMeiOoaVHTM4Ub73d4xBinVkItxWJdsq62T8kUhYwiHlxkTL4H3A6yNNrXOgJDOWy-ATs6Ul7QRmh9tCIZfFxX7_2USA/w400-h390/back%20to%20normal.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">Moving back to centre: fluid can initially access the 'clear path'<br /></span></span><span style="font-family: arial; font-size: x-small;">The slide valve initially holds one disc open. </span><br /><br /></td></tr></tbody></table></div><div style="text-align: justify;"><b style="font-family: arial;">Removal</b></div><div style="text-align: justify;"><span style="font-family: arial;">As with the priority valve, the front height corrector is tucked away behind the shield in the left hand wheel arch. It's bolted to the suspension unit, over the top of the anti-roll bar.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEH4iEWfHToopDPGsHS-i0XEdC6Q0qxF5ehuVDxmvek6Pj6aw221J1H62s6TMCYw5lAof683Fo4lnnNJpoOzvBmfT8LgL_cr_b4Ht7NngL9Z3Pbg5MabV9JUnWLQcGZqYKwrSi6MLOSvsUKhwyZtySsWqL0xMWrxWYdNyeebUhXDeyh-WyFWhE7w/s3264/IMG_0644.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEH4iEWfHToopDPGsHS-i0XEdC6Q0qxF5ehuVDxmvek6Pj6aw221J1H62s6TMCYw5lAof683Fo4lnnNJpoOzvBmfT8LgL_cr_b4Ht7NngL9Z3Pbg5MabV9JUnWLQcGZqYKwrSi6MLOSvsUKhwyZtySsWqL0xMWrxWYdNyeebUhXDeyh-WyFWhE7w/w400-h300/IMG_0644.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Front height corrector and connections on the suspension unit</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Instructions for removing the front height corrector aren't included in manual 814 (though may have been added to some PDF copies you can find on line). Those instructions are lifted from Operation DX. 433-1 in earlier manual 518. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibU6k59Jy8i_3K09e8qJh4IXllwojhCoJ7whUhwfgLml6Vf2Qi2ONjcs8gFQdKJIAGWKaeOl2JLqSxiOc_anvth8spYTDqSJ89DvS8bivLnnW1sGWO5NgtAv4155qhfyQTJjcq5CB3-eBljpEGO31gwS9PWK7jio7L9HcR-D7EKsZM-4f3TLWB_g/s1141/518.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="802" data-original-width="1141" height="281" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibU6k59Jy8i_3K09e8qJh4IXllwojhCoJ7whUhwfgLml6Vf2Qi2ONjcs8gFQdKJIAGWKaeOl2JLqSxiOc_anvth8spYTDqSJ89DvS8bivLnnW1sGWO5NgtAv4155qhfyQTJjcq5CB3-eBljpEGO31gwS9PWK7jio7L9HcR-D7EKsZM-4f3TLWB_g/w400-h281/518.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Extract from Manual 518</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I removed my front height corrector as part of work to remove the suspension unit it's bolted to - and as part of that work I removed all the pipework in the wheel arch. If you just want to remove the height corrector, you only need to disconnect the three hydraulic pipes connected to it plus the return line. Other than that, it's just held to the suspension unit by two bolts.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Repair kits can be bought from the usual suppliers. The usually include the two outer rubber dust covers plus the two inner rubber diaphragms and the steel belts that hold them in place. Citrotech sell an expanded kit that includes the inner metal discs and springs. If you don't fancy rebuilding yours, you can also get them on a part-exchange basis. Again, Citrotech offer a 'deluxe' version that has been re-bored and includes an oversized slide valve - bring performance back to 'as new'.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8pi-zR2lVg6R1vQvDGy9U102dYvMaaCchZIZMvtHeWIRjN0G_8Kn-Fr4At3DjoXKilEAT1i2zLHOZN_VcU03Ccm9MmyiDsBAAS5zaL5p6i31CifH9eL7PkN1CD4ORP8zUwutILSb5tDPmjUzUyijfaAYpSOfkC76AjMAuZpHNjC0qxa_mUSqlaw/s1160/large.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="743" data-original-width="1160" height="256" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8pi-zR2lVg6R1vQvDGy9U102dYvMaaCchZIZMvtHeWIRjN0G_8Kn-Fr4At3DjoXKilEAT1i2zLHOZN_VcU03Ccm9MmyiDsBAAS5zaL5p6i31CifH9eL7PkN1CD4ORP8zUwutILSb5tDPmjUzUyijfaAYpSOfkC76AjMAuZpHNjC0qxa_mUSqlaw/w400-h256/large.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Citrotech's 'large' rebuild kit has more parts</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Dismantling and reassembly instructions are also in manual 518 - at Operation DX. 433-3. Just bear in mind that manual 518 is from 1966 and before the introduction of LMH. So, if your car and so height corrector operate on LHM, where it advises to wash parts in alcohol - don't. For LHM vehicles, use petrol or white spirits instead.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Dismantling</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">To aid reassembly, before you begin, it's worth taking a reference photo of the balljoint..... You should find it is at about 15 degrees to the horizontal. That's "should". The repair manual isn't at all helpful on this point. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirCjhppSDwY0X4giuaNtV1aJJHEAZMLZ8JREEkTTpdYNTA3efJ7HIyWv1AH4LCliijcztk8ZTkHb_Kybbf7fgQqemBAB9f_PdwcU5BN34mL4ouwu7S-ho-CMBOBoDt_0agHJCDPqVj49jrhDGRp2H8Yc2xCnntEM7CEftSkeChel3h0Z2uk098bA/s1404/15%20degrees%20pic%20copy.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="465" data-original-width="1404" height="213" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirCjhppSDwY0X4giuaNtV1aJJHEAZMLZ8JREEkTTpdYNTA3efJ7HIyWv1AH4LCliijcztk8ZTkHb_Kybbf7fgQqemBAB9f_PdwcU5BN34mL4ouwu7S-ho-CMBOBoDt_0agHJCDPqVj49jrhDGRp2H8Yc2xCnntEM7CEftSkeChel3h0Z2uk098bA/w640-h213/15%20degrees%20pic%20copy.jpeg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">15 degree angle - according to the workshop manual</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The guide lines it shows don't line up with the angle of the actual. And what is the 'horizontal' reference point? I added the yellow lines, but they still don't help. I took the vertical to be based on the surfaces where the hydraulic connections fit - rather than the angle of the mounting bracket. And so 'horizontal, 90 degrees from that.....I think my ball joint was at about 25 degrees?</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj03jn5re4Q4gOkGTuv9HlUpP4nTvwg5B6NLy7WE_WWKTznnbpS-gmRLgTdRQ4N5814OCFfxTPW_VDwpwsiWR13zhpos3zs59cYIDkBnvQuqk-9neWo6gamQpRkL7nO-4nA8Yw57OQjJT6mzvmwSeuWq_tJFAeYJgwHgaUMXpufCxHANX6hqcbqfQ/s4032/IMG_5325%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj03jn5re4Q4gOkGTuv9HlUpP4nTvwg5B6NLy7WE_WWKTznnbpS-gmRLgTdRQ4N5814OCFfxTPW_VDwpwsiWR13zhpos3zs59cYIDkBnvQuqk-9neWo6gamQpRkL7nO-4nA8Yw57OQjJT6mzvmwSeuWq_tJFAeYJgwHgaUMXpufCxHANX6hqcbqfQ/w400-h300/IMG_5325%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Not 15 degrees......</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I have a couple of spare height correctors and they all seem to be at about this angle. It is easy to alter it later if it proves not to be correct. At the very least, having a photo</span><span style="font-family: arial;"> will also remind you which end of the body the ball join goes on!</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">The rubber dust covers peel off the ends. The cover on the ball joint end can carefully be manoeuvred around the balljoint at this stage - or you can remove the balljoint and the washer beneath it by first loosening the lock nut on top of it. The ball joint part is also threaded.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkFeu1qt3Kvb35BFNa3cCaqO1xo95jNO5oLIF75AIA6ho_tjqFas-XrXDICXkxbyvddLRhNcRiR-zZ5_HYPpjrgBD7ccHZOg0CNZVIvP3UMi4TQOZ7yitkQmP6JwirU-8OuLM87etLa0qABExLdpDgAOxgMACF07BuWXh1bsOxn76k3MzeMVOENA/s4032/IMG_5372.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkFeu1qt3Kvb35BFNa3cCaqO1xo95jNO5oLIF75AIA6ho_tjqFas-XrXDICXkxbyvddLRhNcRiR-zZ5_HYPpjrgBD7ccHZOg0CNZVIvP3UMi4TQOZ7yitkQmP6JwirU-8OuLM87etLa0qABExLdpDgAOxgMACF07BuWXh1bsOxn76k3MzeMVOENA/w400-h300/IMG_5372.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Lock nut on the control ball joint</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Removing the rubber dust cover from the other end similarly reveals.....</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEsvPYKWUxzj_BtgDatCCNkQgXdW-stt0dsgqrBCqPvIRVjyAMz21_jUJ4w2XDbA58YzMH0Cuoh01ZfPGCDodSpoD9oLVeSH2xluFMvvZMeVIavDK7fRztmvKwkrChpiMu2W_WAjnCxaxAGcDBoThYwOKYlSwEnVnF8n2XPbnXEIGKbeoC_ttn2A/s4032/IMG_5331.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEsvPYKWUxzj_BtgDatCCNkQgXdW-stt0dsgqrBCqPvIRVjyAMz21_jUJ4w2XDbA58YzMH0Cuoh01ZfPGCDodSpoD9oLVeSH2xluFMvvZMeVIavDK7fRztmvKwkrChpiMu2W_WAjnCxaxAGcDBoThYwOKYlSwEnVnF8n2XPbnXEIGKbeoC_ttn2A/s320/IMG_5331.JPG" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Inner rubber diaphragm</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">......another rubber diaphragm. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Removal of the nozzle for the return hose is easy. Note the use of a copper washer as that will need to be replaced.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNCO1yUmefk6ZfrtYTcjIZI9g7AAgOc20tLCIHz5joNFHzneSfjQkfgvjpM3FMwea4wBbfwzKkDqITRxbQoTJuoTrTL4yPsJca1s03qoGi8OnxLU9b6DenfuMrpVwf3iFWfejzdbjlSnqAgtbL6x3kp6kcQ2lEulG392v5Xgxy5bF04NLBuQb4Lg/s4032/IMG_5337.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNCO1yUmefk6ZfrtYTcjIZI9g7AAgOc20tLCIHz5joNFHzneSfjQkfgvjpM3FMwea4wBbfwzKkDqITRxbQoTJuoTrTL4yPsJca1s03qoGi8OnxLU9b6DenfuMrpVwf3iFWfejzdbjlSnqAgtbL6x3kp6kcQ2lEulG392v5Xgxy5bF04NLBuQb4Lg/w400-h300/IMG_5337.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Removing the return pipe nozzle</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The two metal collars around the two inner diaphragms can be carefully prised off and, with the nuts and flat metal discs removed, the inner rubber diaphragms can be removed. If you hope to re-use the diaphragms, be careful not to damage them when you take the collars off. Beneath each diaphragm is another metal disk - dished in this case - and a spring. You are also likely to find a lot of muck.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_zoihvls_cE035HoVZlVpitwQby681EVC1-vG0TGHHq-gLoTzZrgd2pbidzg99oIdfJaCiMPE9HFHcXBuxDzVgsCnWps3xKC5n70E2vs_85l_tvvUd1xQJK3oNCUyJ9lml0yuFjaUTMwH2PtngkRQnXaW2YmFd4UW9uhORge-rIaAe7fraqpGAA/s4032/IMG_5332.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_zoihvls_cE035HoVZlVpitwQby681EVC1-vG0TGHHq-gLoTzZrgd2pbidzg99oIdfJaCiMPE9HFHcXBuxDzVgsCnWps3xKC5n70E2vs_85l_tvvUd1xQJK3oNCUyJ9lml0yuFjaUTMwH2PtngkRQnXaW2YmFd4UW9uhORge-rIaAe7fraqpGAA/w400-h300/IMG_5332.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Metal disc, spring and lots of muck</span></td></tr></tbody></table><span style="font-family: arial;">That muck is also all over the height corrector and in my case I couldn't initially make out any detail.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_GKxQ0NdqSJjdbuH6cfL7aESyU35ZWUuJbwbHhhFW5XfbRrknMUb6tvvxHR6XTPU60b6rmQ3cD2r5JONudC-fqwfdTqp2P54QdTfDJ-hg479AHxipejcFvtqeNxCBhc9mpuqSjVYRU1rUzGZU8gByXVkrJMsZnIzeKfBTf25sCRROsHbfVBTjsA/s4032/IMG_5334.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_GKxQ0NdqSJjdbuH6cfL7aESyU35ZWUuJbwbHhhFW5XfbRrknMUb6tvvxHR6XTPU60b6rmQ3cD2r5JONudC-fqwfdTqp2P54QdTfDJ-hg479AHxipejcFvtqeNxCBhc9mpuqSjVYRU1rUzGZU8gByXVkrJMsZnIzeKfBTf25sCRROsHbfVBTjsA/w400-h300/IMG_5334.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Muck in the height corrector</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">By now both ends of the corrector will look pretty similar - especially if it's covered in dirt like mine was. Cleaning some of that dirt off reveals that at both ends there is a circlip loosely holding a disc valve. Removing one or other circlip and disc valve enables the slide valve (for that is what it is) to be pulled out.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqXwcjw3jyIo6QYGxtIdtruSks4MTzIebU4DTuvTkWjr8RTDWVnBRCKtz8WwIO7qIhkQeDi9gO3rQaqPK4snR9-kxxZB6UTI0gBScHN9DjuyiZPOTpAy4Yfd8hIYiGlr1sf6RK2oD9IgEio3EGLlTYIaWmZqAKzZcg3HilAtHSHCviizYjogqtSQ/s4032/IMG_5340.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqXwcjw3jyIo6QYGxtIdtruSks4MTzIebU4DTuvTkWjr8RTDWVnBRCKtz8WwIO7qIhkQeDi9gO3rQaqPK4snR9-kxxZB6UTI0gBScHN9DjuyiZPOTpAy4Yfd8hIYiGlr1sf6RK2oD9IgEio3EGLlTYIaWmZqAKzZcg3HilAtHSHCviizYjogqtSQ/w400-h300/IMG_5340.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Removing the slide valve</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Outside of the disc valve perimeter you will notice holes. Small at one end and slightly larger at the other. These are part of the dash pot. (The 'easy route' - the clear path - is within the area covered by the disc valve).</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-4C1PNoUANpxwcdHDp0ykfJWMjkHwI5tuLC0-HPFT4fej85BgjHMqhjCYli-Mt1RQ5s8AJjstRwiwfLzCuMCcZ0RDKFIM8nsn72s4r960HXnc4-_13HLkUEEkjPkdr4-uc7JAcA31Mq3t1m3y8BJBO0VUGgli7k4ZF-012vel4wU93GLwJRR9Yg/s4032/IMG_5339.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-4C1PNoUANpxwcdHDp0ykfJWMjkHwI5tuLC0-HPFT4fej85BgjHMqhjCYli-Mt1RQ5s8AJjstRwiwfLzCuMCcZ0RDKFIM8nsn72s4r960HXnc4-_13HLkUEEkjPkdr4-uc7JAcA31Mq3t1m3y8BJBO0VUGgli7k4ZF-012vel4wU93GLwJRR9Yg/w400-h300/IMG_5339.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Note the small hole in the body</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Cleaning the larger dash pot hole up will reveal the head of a threaded insert. To remove this you need to make a 'key' by cutting a shallow, but wide groove in the end of something like an M7 bolt. It needs to be narrow enough to go into the hole, but wide enough to accommodate having a wide groove cut in it.If you use a bolt, it's also worth filing the threads down a little, so they do not catch in the hole. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAK3e9DbdJkvpZmWL2fyY0PmqiNJINDiFCj_pG4v9zArBN3w8j2SreUfeQfP0k_wDkYhsAO05ClnMpO5OWLH-gf_ZsetXbbwhPwwp0yK-yjl89KSuFHHsRWu8eD7miSBQcBpezK53BkKOoB6iNWJ4pHkt31flRvN-U6pod4EZI1oUj5hidVvYN_g/s4032/IMG_5351.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAK3e9DbdJkvpZmWL2fyY0PmqiNJINDiFCj_pG4v9zArBN3w8j2SreUfeQfP0k_wDkYhsAO05ClnMpO5OWLH-gf_ZsetXbbwhPwwp0yK-yjl89KSuFHHsRWu8eD7miSBQcBpezK53BkKOoB6iNWJ4pHkt31flRvN-U6pod4EZI1oUj5hidVvYN_g/w400-h300/IMG_5351.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">'Key' to loosen the restrictor cap on the height corrector</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Beneath this threaded insert are the restrictors: a series of VERY small discs and spacers that, together, serve to slow the flow of LHM.....As well as being very small these are VERY delicate and VERY easy to lose. Before you get stuck in, here is an idea of what is down that hole.....</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0XPEoBLXwB8_O3YzD0AlP6WqQDxYg8ci2mdkEMlRJ8lVuInkvj7Madqo4a33KBHWJuXuosl0Kfb3C4cVkGug6QzZ4dIDEDiuRHVrnSYDHikPg67XABVJeQ5eOfZaEXvDze7J-6trmyFolloEPHvC7YwFhFuooN013gI2UZW222H0Ab5Wl23hVkg/s1326/Restrictor.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="798" data-original-width="1326" height="241" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0XPEoBLXwB8_O3YzD0AlP6WqQDxYg8ci2mdkEMlRJ8lVuInkvj7Madqo4a33KBHWJuXuosl0Kfb3C4cVkGug6QzZ4dIDEDiuRHVrnSYDHikPg67XABVJeQ5eOfZaEXvDze7J-6trmyFolloEPHvC7YwFhFuooN013gI2UZW222H0Ab5Wl23hVkg/w400-h241/Restrictor.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Restrictors and spacers in the dash pot</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Either side of a central spacer is a stack of three intermediate spacers, sandwiched between four restrictor discs. So that's one central spacer, six intermediate spacers and eight restrictor discs. The restrictor discs looks similar to sequins but are much thinner and with a much smaller hole through them. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">With the screw cap removed, the way to get everything out is to carefully push the stack out from the 'smaller hole' end. It's advisable to use a blunt, flat ended tool to do this - so that you don't skewer the very delicate restrictor discs. Ideally it should be as wide in diameter as the small hole allows - so that it is pushing on a bigger surface.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Now it doesn't take much to push the stack out at all. But the problem is that, on the way out, the edges of the delicate restrictor discs can catch on the threads where the cap fits - so don't push too hard or too violently. When the stack does come out be very careful. The mucky parts are stuck together and hard to see, but will stick yo your fingers in a jiffy and are easily dropped or lost without realising.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV7GjFfhGKDlov79b4FSpAu5IhP55deHAlXWQe3C0UkvySdVe42dTXLOxPAbZ32rba2e-48PXWj6TF96qOOI4BC69AM0DN5tPku0S5NBXBVR2dg0Uu68108v2tpCu8n2Nyfr9CPvqiAgERbaoR4sVFpXB_gRjbsAklcxJwo700UQWfQBbJK6e4qA/s4032/IMG_5345.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV7GjFfhGKDlov79b4FSpAu5IhP55deHAlXWQe3C0UkvySdVe42dTXLOxPAbZ32rba2e-48PXWj6TF96qOOI4BC69AM0DN5tPku0S5NBXBVR2dg0Uu68108v2tpCu8n2Nyfr9CPvqiAgERbaoR4sVFpXB_gRjbsAklcxJwo700UQWfQBbJK6e4qA/w400-h300/IMG_5345.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Eight restrictors, six intermediate spacers and a central spacer</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">And that is everything disassembled.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I gave everything a rinse in white spirits and the larger parts a delicate scrub with a toothbrush. I paid particular attention to getting out any slithers of rubber pipe seals from the threads of the connections. I have an ultrasonic cleaner and put the larger parts through that. It went down like this.</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dwAaw1KZWCMQzA169hDxq2KBfEWU4zlwxNphxJ5A3NNwBRVyb5zM_6vNSqaB8vDEjt1qImK2_xASe6aJzJxxA' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div><div style="text-align: center;"><span style="font-family: arial; font-size: x-small;">VIDEO: Use of an ultrasonic cleaner</span></div></div><div style="text-align: left;"><div style="text-align: justify;"><span style="font-family: arial;">The buzzing is the high speed vibration of the cleaner. The dirt and muck just jumped off in wispy trails....... I suspended the delicate slide valve on a piece of wire - rather than have it rattle around in the cage and get damaged.I rinsed off and dried the larger parts with compressed air and then gave the parts a brush over with LHM - as protection prior to assembly.</span></div></div><div style="text-align: left;"><span style="text-align: justify;"><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">The smaller parts were too delicate to risk losing in the cleaner. Those just got another soak in white spirit and a wipe down with a rag. You may be tempted to poke the holes through with a pin. Don't. the holes are smaller than that and their size is an important factor in making the height corrector function as it should. Instead, hold them up to the light to see if the holes are clear.</span></div></span></div><div style="text-align: left;"><span style="font-family: arial;"><span style="text-align: justify;"><br /></span></span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Reassembly</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">When it came to reassembly, the parts were so small and easy to lose that I decided to assemble them on a piece of black cloth - just so that I could keep an eye on them. I started by reinstalling the restrictors and spacers in the dash pot. This was easier than taking the parts out. Remembering the correct order of parts........</span></div><div style="text-align: justify;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqjp5-UZPVLBuXDKOgX-a-LDaZ5J79Yf6hMlLcM2ncND6_YPznU5NeY0CeJ1yNHITfs_jN4gWUtWByHhPoiH1hTH4ovG0LkDINSRyYYEwH6ga2i6w2MLtfB6g7bnm3IFIvujXHQ7tdQ5kLS-qUYMkmZLa_E9KDbdJLZIgRnmN5f3uaxBRYbXiGJQ/s1383/order.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="595" data-original-width="1383" height="173" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqjp5-UZPVLBuXDKOgX-a-LDaZ5J79Yf6hMlLcM2ncND6_YPznU5NeY0CeJ1yNHITfs_jN4gWUtWByHhPoiH1hTH4ovG0LkDINSRyYYEwH6ga2i6w2MLtfB6g7bnm3IFIvujXHQ7tdQ5kLS-qUYMkmZLa_E9KDbdJLZIgRnmN5f3uaxBRYbXiGJQ/w400-h173/order.jpeg" width="400" /></a></div></span></div><div style="text-align: justify;"><span style="font-family: arial;">............I gave each piece a wipe over with LHM before carefully dropping it into the hole. I used the end of a cocktail stick to encourage each one to lay flat but, once they'd dropped below the level of the threads they had some 'wiggle room' and were easily manoeuvred.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkCSZ6lZ8D8JYUVinn6Bo4tDVgOBR3LIgP1KJg0FhfOKxX6ekmw5Dq74SD284RS7fsci9mXFgv8QUruxC7dyoOse-7pkDgYZ4LPJuzTAedonPw7os99eb2_0JCzSXjVOP3tTynLr2mLXjPLRVqd933RyUss3fK5OEhjz0Vh-SDEhoNH0K0Prl_dA/s4032/IMG_5347.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkCSZ6lZ8D8JYUVinn6Bo4tDVgOBR3LIgP1KJg0FhfOKxX6ekmw5Dq74SD284RS7fsci9mXFgv8QUruxC7dyoOse-7pkDgYZ4LPJuzTAedonPw7os99eb2_0JCzSXjVOP3tTynLr2mLXjPLRVqd933RyUss3fK5OEhjz0Vh-SDEhoNH0K0Prl_dA/w400-h300/IMG_5347.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Restacking the dash pot - halfway there.....</span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial; text-align: justify;">The last restrictor went in and was happy to lay flat. You can just about see it - and the tiny hole in it's middle - in this photo below. And then the cap was replaced using the special tool I'd had to make. I just nipped it up.</span></div><div style="text-align: left;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj20NtPWRcxiWBqQQ0S1xO5oY8RUiuG8uPapeGlnY0VCCVWDfVJNRgjZdF6cgUaRfV96j8K_jpdjwY7BZ3eHcOw6r4WaxmLoFqZKbXbPAIwJySq7599Qaw7aUHwC0RG8EtYl7OKoDRjDglEVTM4LUnAVFHpY7ghNhTwhuhbJisBCwhxRr1-7uvv-Q/s4032/IMG_5348.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj20NtPWRcxiWBqQQ0S1xO5oY8RUiuG8uPapeGlnY0VCCVWDfVJNRgjZdF6cgUaRfV96j8K_jpdjwY7BZ3eHcOw6r4WaxmLoFqZKbXbPAIwJySq7599Qaw7aUHwC0RG8EtYl7OKoDRjDglEVTM4LUnAVFHpY7ghNhTwhuhbJisBCwhxRr1-7uvv-Q/w400-h300/IMG_5348.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Last restrictor in the dashpot</span></td></tr></tbody></table></span></div><div style="text-align: left;"><span style="font-family: arial; text-align: justify;">Turning my attention to the slide valve assembly, I clipped one of the disc valves to one of the ends using a circlip. The disc is intentionally loose as it serves as plug depending on the position of the slide valve.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEib2o8N7eXDBB3PSJO6pHqP6AKh1ad-nfYx-16AwaJRP0G5p1AHSjyN_gncocbVDOVbmu9LtIum2wxQkwL8nHQzTr4rpwgBBbsfcIunayXY1qF5qFvcYhNZcl8G9PApfet68YapWhd6zqJvHfudkepeo36JuytAR4n7Gv4Swl7A_eyc2QRKbiamCA/s4032/IMG_5354.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEib2o8N7eXDBB3PSJO6pHqP6AKh1ad-nfYx-16AwaJRP0G5p1AHSjyN_gncocbVDOVbmu9LtIum2wxQkwL8nHQzTr4rpwgBBbsfcIunayXY1qF5qFvcYhNZcl8G9PApfet68YapWhd6zqJvHfudkepeo36JuytAR4n7Gv4Swl7A_eyc2QRKbiamCA/w400-h300/IMG_5354.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Adding a disc and retaining circlip.<br />Note that the disc has some freedom of travel</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Before reinserting this in the height corrector body it's important to realise that the two ends are different. One end has a longer thread to accommodate the balljoint and lock nut.</span></div><div style="text-align: left;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyYLt80AyO4kWLES1sewiINUfqZUvUg9q2iCbxJlL80RbdWtrZsLyEfi1Kkk5L46HDqe5qrGADi4lu6Psh8Ly4i50LdlR1NVvbPzJ7b0kwsiLIwQU2PlVfQDfRkv5exqIrVh1QKQSIaJOzfZ-vsS1XFTBk0DtCGvl87X4LV-TLnLPqGpOo1-ZMlg/s4032/IMG_5362.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyYLt80AyO4kWLES1sewiINUfqZUvUg9q2iCbxJlL80RbdWtrZsLyEfi1Kkk5L46HDqe5qrGADi4lu6Psh8Ly4i50LdlR1NVvbPzJ7b0kwsiLIwQU2PlVfQDfRkv5exqIrVh1QKQSIaJOzfZ-vsS1XFTBk0DtCGvl87X4LV-TLnLPqGpOo1-ZMlg/w400-h300/IMG_5362.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Note that the threaded ends are slightly different lengths </span></td></tr></tbody></table></span></div><div style="text-align: left;"><span style="text-align: justify;"><span style="font-family: arial;">With one disc valve now fitted, I lubricated the slide valve - and the bore it would go in - and inserted it so that the longer threaded end would be on the correct side for the balljoint. Over this was placed first a spring (with it's smaller end towards the circlip)......</span></span></div><div style="text-align: left;"><span style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSDsPeRn04BFkpg18J8zqTrWloakA_hKoskflesUtWub5v9eAt_9hjpcifwZyCajr1yBM_AQYirUl98e7hQK70LUaYTvdphg6fD2UVq9vX_6-Ml9a0njXSZoDIoHvJ6gZCQHCYCivMea-46mpOhWqqM6RURWmDCo50qG37UY2gPJLn0RNlIe40TQ/s4032/IMG_5364.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSDsPeRn04BFkpg18J8zqTrWloakA_hKoskflesUtWub5v9eAt_9hjpcifwZyCajr1yBM_AQYirUl98e7hQK70LUaYTvdphg6fD2UVq9vX_6-Ml9a0njXSZoDIoHvJ6gZCQHCYCivMea-46mpOhWqqM6RURWmDCo50qG37UY2gPJLn0RNlIe40TQ/w400-h300/IMG_5364.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial;"><span style="font-size: x-small;">One of the weak springs that hold a disc valve closed</span></span><br /></td></tr></tbody></table></span><span style="font-family: arial; text-align: justify;">........and then a metal cup.</span></div><div style="text-align: left;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX2fD-Nr-lxwL9XWHaly7ay1Xup31DEdoRb6X5HbWfsOKaYeyBijjalVp83v6m2MMnYs9i5JaX0UhG-0TehloMSRoEDaVxcW50c9c-tEeOlcRbIMLMvJKOe9YpGGJNAScvV8VOnOZf3la0QwpqoBhSfZEM58w_ug95pfk0xnoARFTIvwnKN4MCOg/s4032/IMG_5365.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX2fD-Nr-lxwL9XWHaly7ay1Xup31DEdoRb6X5HbWfsOKaYeyBijjalVp83v6m2MMnYs9i5JaX0UhG-0TehloMSRoEDaVxcW50c9c-tEeOlcRbIMLMvJKOe9YpGGJNAScvV8VOnOZf3la0QwpqoBhSfZEM58w_ug95pfk0xnoARFTIvwnKN4MCOg/w400-h300/IMG_5365.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Spring and cup fitted.</span></td></tr></tbody></table><br /><span style="text-align: justify;">Note which way up the </span></span><span style="font-family: arial;">metal cup fits. It nestles in the spring. If you get the spring the wrong way up the cup doesn't fit - so you'll soon know. After this I carefully put back one of the rubber diaphragms. These had been cleaned, dried and I'd rubbed them over with a little LHM.</span></div><div style="text-align: left;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjacA-2I29Xt-5qOPOWo_hXFdwu2_tW-g-knffZJ62GL8GhywGWAimDIlYhGGzUot7hTeAly5sbHC5Yju1NCIzWELnGtCwbPZWwwLzKeBGr_Uh1HadwIqZYFeGXePwCxpKMy_x3Tedour6fsmsimnKNuoGWFcsVX7lKKPFQEinsNKXn-n1V-RHlog/s4032/IMG_5367.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjacA-2I29Xt-5qOPOWo_hXFdwu2_tW-g-knffZJ62GL8GhywGWAimDIlYhGGzUot7hTeAly5sbHC5Yju1NCIzWELnGtCwbPZWwwLzKeBGr_Uh1HadwIqZYFeGXePwCxpKMy_x3Tedour6fsmsimnKNuoGWFcsVX7lKKPFQEinsNKXn-n1V-RHlog/w400-h300/IMG_5367.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">The green mark means the rubber part is 'LHM friendly'</span></td></tr></tbody></table></span></div><div style="text-align: left;"><span style="font-family: arial;"><span style="text-align: justify;">With a flat metal outer disc </span></span><span style="font-family: arial;">added over the diaphragm, a nut (or washer, ball joint and nut) can be added and tightened. If you find yourself working on the ball joint end first, don't worry about it's orientation at this point, the slide valve can still be rotated in the housing.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBxufLK2KGF2l20otS6WX6kP-gdfXXDZAzBrx2M3r8ex_q4eD5njsieHFPWcen--_SIXX2LSKRo2DsLsHo56f_NqHdRoquG0X8oSe6Dl96GkBxKicK4AMJpQ0HRFhnFDAO8VDX3RpatYUPL1PWBDC5kiouAkcy376RPQOya7mAcqIWe07PLq-5mA/s4032/IMG_5372.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBxufLK2KGF2l20otS6WX6kP-gdfXXDZAzBrx2M3r8ex_q4eD5njsieHFPWcen--_SIXX2LSKRo2DsLsHo56f_NqHdRoquG0X8oSe6Dl96GkBxKicK4AMJpQ0HRFhnFDAO8VDX3RpatYUPL1PWBDC5kiouAkcy376RPQOya7mAcqIWe07PLq-5mA/w400-h300/IMG_5372.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Ball joint refitted</span></td></tr></tbody></table><span style="font-family: arial;">Now. At this point the workshop manual says that BOTH ends should have the diaphragms fitted and the height corrector should now be primed/ filled. This is covered in manual 518.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSaKGKHBUzSmWi2PXMl1gyfeNsoVWyoRc5l9GUGtrPomWu1TunpEQgU4KX197hguZXtXAYwtfs2SWzqklYbj6VAGdy_wtrVbjarFXfcUmPcvQcJqBKn-Wkfg87DgHaBgTpaLBkZ7ysxPDYWcQgrYn1L-_9KdVrcaj4MMGXCQByWchrV1L8xCH-RA/s1197/rig.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="794" data-original-width="1197" height="265" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSaKGKHBUzSmWi2PXMl1gyfeNsoVWyoRc5l9GUGtrPomWu1TunpEQgU4KX197hguZXtXAYwtfs2SWzqklYbj6VAGdy_wtrVbjarFXfcUmPcvQcJqBKn-Wkfg87DgHaBgTpaLBkZ7ysxPDYWcQgrYn1L-_9KdVrcaj4MMGXCQByWchrV1L8xCH-RA/w400-h265/rig.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Rig for filling a height corrector........</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The idea is to peel back slightly, the diaphragms, and then gently force LHM into the body through the overflow/ return orifice until it leaks out of the gap behind the diaphragm. Only at that point should the steel bands be added. and the overflow orifice sealed.</span></div><div style="text-align: left;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I chose not to do this at this time - as I don't have a rig and pump set up to fill the height corrector. It's possible I might chose to make one, or perhaps find another way to fill the corrector before I fit it.</span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAPJYr7SPBhDIG-8JB2cO21zn-fx-j5HcFxVnQcm4qBJjbheT2GGo9LCYSuMMzXJh_CUjSlRzwsJj60IN60UscFP1tXWK92TMGNAzTDKPnNQgSAL_PwCr-Ggok2HwfVFhZITZMNOsnVSK-bbwnCY2HHn53a38FCByIrEyT6fenJtQDqNXvXzm4qQ/s4032/IMG_5373.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAPJYr7SPBhDIG-8JB2cO21zn-fx-j5HcFxVnQcm4qBJjbheT2GGo9LCYSuMMzXJh_CUjSlRzwsJj60IN60UscFP1tXWK92TMGNAzTDKPnNQgSAL_PwCr-Ggok2HwfVFhZITZMNOsnVSK-bbwnCY2HHn53a38FCByIrEyT6fenJtQDqNXvXzm4qQ/w400-h300/IMG_5373.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Steel band refitted</span></td></tr></tbody></table><div style="text-align: left;"><span style="font-family: arial;"><span style="text-align: justify;">Anyway. My first steel band went on.....I'm told the steel bands can be quite tight, but I was re-using the original rubber diaphragms and steel bands and, with a smear of LHM to help them, they came together nicely.</span></span></div><div style="text-align: left;"><span style="font-family: arial;"><span style="text-align: justify;"><br /></span></span></div><div style="text-align: left;"><span style="font-family: arial;"><span style="text-align: justify;">The other end got the same treatment. If you've previously fitted the ball joint end, carefully rotate the inner assembly to give yourself the '15 degree angle' you had before dismantling. Now fit and tighten the nut to the other end. Alternatively, if you first fitted the 'nut end', fit the ball joint and use it's lock nut to give you the magical (mythical?) 15 degree angle.....</span></span></div><div style="text-align: left;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjr0_n6XD076qW1BVtLHQkAeKGIiN4Cub87mKsYi6G2i8_2sT1Y6dyPts0gjdvfW0E2y7y27JaHDwQ38gMU6BlrIiKcy3KURlGzo6XMdLjnQmqcVY7bNa2VF0Xdh5aPLxpGfkCe6izzmVaajmUBdwP8-xJ0ipwaJ1yQoesRGpQ6CmqkJ1bEmf_YqQ/s4032/IMG_5374.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjr0_n6XD076qW1BVtLHQkAeKGIiN4Cub87mKsYi6G2i8_2sT1Y6dyPts0gjdvfW0E2y7y27JaHDwQ38gMU6BlrIiKcy3KURlGzo6XMdLjnQmqcVY7bNa2VF0Xdh5aPLxpGfkCe6izzmVaajmUBdwP8-xJ0ipwaJ1yQoesRGpQ6CmqkJ1bEmf_YqQ/w400-h300/IMG_5374.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Both ends done now</span></td></tr></tbody></table></span></div><div style="text-align: left;"><span style="text-align: justify;"><span style="font-family: arial;">The last jobs were to refit the outer rubber dust covers and to</span></span><span style="font-family: arial; text-align: justify;"> refit the </span><span style="font-family: arial; text-align: justify;">nozzle for the return pipe - using a new copper washer.</span></div><div style="text-align: left;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBa02oQbbnQk-z7Q1VA3WTf_2qF3gngnN7b6F_yNRGOa1hQEwaZyukYbHIn957dARrBY7KNFK9tv14fIH9lXvOTluUwqNDKAvUsbtwHlujpptGq9Rr67torf1_RW3VcBNQVyUYGRCdAFy7at1gBK_WsoXcC7qNKFrA8oE5cYvjOQp1Ae_0c0KCBA/s4032/IMG_5375.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBa02oQbbnQk-z7Q1VA3WTf_2qF3gngnN7b6F_yNRGOa1hQEwaZyukYbHIn957dARrBY7KNFK9tv14fIH9lXvOTluUwqNDKAvUsbtwHlujpptGq9Rr67torf1_RW3VcBNQVyUYGRCdAFy7at1gBK_WsoXcC7qNKFrA8oE5cYvjOQp1Ae_0c0KCBA/w400-h300/IMG_5375.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Refitting the nozzle - with a new copper washer</span></td></tr></tbody></table></span></div><div style="text-align: left;"><span style="font-family: arial;"><br /></span></div><div style="text-align: left;"><span style="font-family: arial;">Now that I type this up, I'm tempted to see what I can do to prime the height corrector before I fit it. Fluid is fed in through the return nozzle. Maybe a big syringe will allow me to create enough pressure to get the fluid into both chambers? Guess I'll have to wait and see....</span></div><div style="text-align: left;"><br /></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-2106019991277677862022-09-24T17:40:00.006+00:002023-05-24T20:32:12.398+00:00 Priority Valve - Stripdown And Overhaul<div><span style="font-family: arial; text-align: justify;">As I prepare to reinstall the hydraulics, I serviced the Priority Valve.</span><span style="font-family: arial; text-align: justify;"><br /></span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiZgOJMEtOhtEGkcEZiyAzeWIv-aTUQJYYHdOuEL74f69s7gHqJHSzRcmzy9mCFBag8vYrlp1IP3zkQwxfm6rsQK9YRqfNQmioMtdGuUsyoLLB2DDbmIYUIy1CpTC7u5pRvt6XUMaB4a09Sy9aW8fnIRXzCqZZXAls0MnA2VWGFf97SRcHzH3YfQ/s4032/IMG_5476.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiZgOJMEtOhtEGkcEZiyAzeWIv-aTUQJYYHdOuEL74f69s7gHqJHSzRcmzy9mCFBag8vYrlp1IP3zkQwxfm6rsQK9YRqfNQmioMtdGuUsyoLLB2DDbmIYUIy1CpTC7u5pRvt6XUMaB4a09Sy9aW8fnIRXzCqZZXAls0MnA2VWGFf97SRcHzH3YfQ/w400-h300/IMG_5476.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">A DS priority Valve</span></td></tr></tbody></table><div style="text-align: justify;"><span style="font-family: arial;">The priority valve was fitted to DS models from December 1967 onwards. So my car would have been among the first to have them fitted. It was introduced as a safety feature and replaced a distribution block that had some of the same function. The function of the priority valve is, in the event of major loss of hydraulic fluid, to divert fluid and pressure from the suspension circuits to the brake circuit. The brakes are given priority. Hopefully for reasons that are obvious to you. </span><span style="font-family: arial;">Generally, ID cars have a different brake mechanism and so, instead of a priority valve, they have a ‘security valve', but the two have a lot in common. I think that the DS brake system has an additional safety valve and a switch for a 'low pressure' red warning light on the pedal assembly. The simpler ID system doesn't have that extra safety valve and it's equivalent to the priority valve has a red warning light switch fitted.</span></div><div style="text-align: left;"><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><span style="font-family: arial;"><div style="text-align: justify;">The priority valve is essentially a non-return valve. Under normal conditions (normal hydraulic pressure) a spool valve - compressed against a spring - allows fluid to flow through all appropriate circuits. When there is a significant fluid loss and drop of pressure, the spring is able to expand and push back against the spool valve - effectively closing one fluid route and diverting fluid and pressure the the brake circuit. You will understand the benefit of being confident that the priority valve is working properly.</div></span></div><div style="text-align: left;"><span style="font-family: arial;"><br /></span><span style="font-family: arial;">When you start the car, pressure starts to build. Pressure is fed initially to the brake circuit. </span><br /><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiNze2s7IapqdiHSIf-0tFh2qW7q7v242tbyQAGVGwY5P_GFOwjWdIegOadbzylb_PklTrD6yi3t9BrhgLKCgapAHR0rJh7oXY3wu6E3ZMrGDGy7sL091pkz3q6Tbsq0kAeUKEfMdBIvacuu1TAAn-tQgmx3fC4Fk46egIMaGRJmlwaG5T-oGSvw/s1279/priority%20valve%20cutaway.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="728" data-original-width="1279" height="228" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiiNze2s7IapqdiHSIf-0tFh2qW7q7v242tbyQAGVGwY5P_GFOwjWdIegOadbzylb_PklTrD6yi3t9BrhgLKCgapAHR0rJh7oXY3wu6E3ZMrGDGy7sL091pkz3q6Tbsq0kAeUKEfMdBIvacuu1TAAn-tQgmx3fC4Fk46egIMaGRJmlwaG5T-oGSvw/w400-h228/priority%20valve%20cutaway.jpeg" width="400" /></a></div></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td class="tr-caption" style="text-align: center;"><div><span style="font-family: arial; font-size: x-small;">Initial pressure to the brake circuit</span></div></td></tr></tbody></table><span style="font-family: arial;"><div style="text-align: justify;">As pressure builds it is sufficient to compress the valve against the spring and allows access for pressure also to be fed to the suspension circuit.</div></span><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSQg4ymoR12ULin_e2e3bB_9NRgjIbjXEqKLnJmqPXeWkzVj1-_CtIcSAp1t4f07c4WNidBjTRI9gI8HJwztVNHn7NSt2ERgzjxZc607uiPzVHBUTYBjRh9rv5v2d9VuDxh8mytcXmPDV5Htf4nBrMHST08N0Ms465n628mCj0r5CwU7O9pfqCLw/s1279/priority%20valve%20cutaway%20copy.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="728" data-original-width="1279" height="228" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSQg4ymoR12ULin_e2e3bB_9NRgjIbjXEqKLnJmqPXeWkzVj1-_CtIcSAp1t4f07c4WNidBjTRI9gI8HJwztVNHn7NSt2ERgzjxZc607uiPzVHBUTYBjRh9rv5v2d9VuDxh8mytcXmPDV5Htf4nBrMHST08N0Ms465n628mCj0r5CwU7O9pfqCLw/w400-h228/priority%20valve%20cutaway%20copy.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Spring compresses: pressure now fed to the suspension circuit</span></td></tr></tbody></table></span><span style="font-family: arial;"><div style="text-align: justify;">So if you are a DS driver, now you know why, when you start the car, the red low pressure warning light goes off, and then the suspension rises. As you can probably work out, if there is a sudden drop in pressure, the spring is able to expand shutting off the suspension circuit - but not the brake circuit.</div></span></div><p style="font-stretch: normal; line-height: normal; margin: 0px; text-align: justify;"><span style="font-family: arial;"><br /></span></p><p style="font-stretch: normal; line-height: normal; margin: 0px; text-align: justify;"><span style="font-family: arial;">Sometimes the spool valve can stick. So if you have problems with your suspension, there is an outside chance its the priority valve playing up - though height correctors would be the prime suspect. </span><span style="font-family: arial; text-align: left;"> If it is sticking, its because muck has gotten into the hydraulic circuit. It's also not unheard of for the push-fit overflow return pipe to fall off the left hand end - causing a leak of hydraulic fluid under the car. In that case </span><span style="font-family: arial; text-align: left;">you can simply push the pipe back on. But you won't know that's the problem straight away as the priority valve is hidden away.</span></p><div style="text-align: left;"><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><span style="font-family: arial;"><div style="text-align: justify;">The priority valve is tucked away behind the metal cover and against the firewall in the left hand front wheel arch. You'll need to remove the wing to remove the cover as one of its bolts is inaccessible otherwise.</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7spIpJC-bWzRLV4AueTgyp_c-LFplb9vVEv_s0EpZ42a_WnDcEkAosEhPLljdG5FZBKeo2IXWp5Ap-oubnMyviZb5YC7nq8Gn5WqUb-YAyiJuU0hmeD0DG9wN4J6z2Te8PBQ9HO0C8Ty59sfHf-bnFRnqa_EyisLS5znZ7NIOKBIdBCTsWsanNg/s960/94889423_10158941887986412_6894597093441142784_n%20copy%202.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="720" data-original-width="960" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7spIpJC-bWzRLV4AueTgyp_c-LFplb9vVEv_s0EpZ42a_WnDcEkAosEhPLljdG5FZBKeo2IXWp5Ap-oubnMyviZb5YC7nq8Gn5WqUb-YAyiJuU0hmeD0DG9wN4J6z2Te8PBQ9HO0C8Ty59sfHf-bnFRnqa_EyisLS5znZ7NIOKBIdBCTsWsanNg/w400-h300/94889423_10158941887986412_6894597093441142784_n%20copy%202.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: small;">Priority valve in the wheel arch</span><br /><span style="font-size: small;">(photo credit Hugh Parris)</span></td></tr></tbody></table><div style="text-align: justify;"><span style="text-align: left;">This was the state of mine. Can you see it?</span></div></span><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOt1MY7FU-ezCJGKNX6ZJqE4MGDHCrEiaRc_NfIRGxpjdudjXUlRvFV-IDUe5qN3MbLgL355m9VBgSyxU7Wz46PUoTD9YnAlciCe0IPUrsZ3WzZSYFosMwfrDDAVl6QTfU6P5q88qc6wqQTZo7fr0XmxVrBIdVq4V4sONjuWpIG1aXTkcGpU77dQ/s3264/IMG_0697.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOt1MY7FU-ezCJGKNX6ZJqE4MGDHCrEiaRc_NfIRGxpjdudjXUlRvFV-IDUe5qN3MbLgL355m9VBgSyxU7Wz46PUoTD9YnAlciCe0IPUrsZ3WzZSYFosMwfrDDAVl6QTfU6P5q88qc6wqQTZo7fr0XmxVrBIdVq4V4sONjuWpIG1aXTkcGpU77dQ/w400-h300/IMG_0697.JPG" width="400" /></a></div></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td class="tr-caption" style="text-align: center;"><div><span style="font-family: arial; font-size: x-small;">My priority valve</span></div></td></tr></tbody></table><span style="font-family: arial; text-align: left;">You'll need to remove some of the hydraulic pipes to gain access to the valve, as well as four hydraulic pipes and a return line on the valve itself. When you undo the hydraulic pipes from the valve, take photos and mark which came from where.</span></div><p style="font-stretch: normal; line-height: normal; margin: 0px; text-align: justify;"></p><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOv8mZUZbwR4FET99x_yvj1zgzHfE6Bux-NvgLmFuEUSQpiso7SZQAEpVDppIVSpAcPOmBAFryuKZQ3QUbYqBaOwpn99w_3g4lp-75PSsQvD6nMuHSl07JJ0RTWFyIxRkHw-8Jm8DGdNsE-9917igJbvPfldO4MR8zhsCbx1jaoRRi1BG8d8kMww/s960/295555102_10160284552359268_3074083631508756430_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="960" data-original-width="720" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOv8mZUZbwR4FET99x_yvj1zgzHfE6Bux-NvgLmFuEUSQpiso7SZQAEpVDppIVSpAcPOmBAFryuKZQ3QUbYqBaOwpn99w_3g4lp-75PSsQvD6nMuHSl07JJ0RTWFyIxRkHw-8Jm8DGdNsE-9917igJbvPfldO4MR8zhsCbx1jaoRRi1BG8d8kMww/w300-h400/295555102_10160284552359268_3074083631508756430_n.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Pipework makes harder to get at the priority valve<br />(photo credit - unknown)<br /><div style="text-align: justify;"><br /></div></span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial;">Rebuilding the priority valve is straightforward though, before you do so, it’s worth sourcing two replacement ‘O’ rings.</span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwkx5r8Kq7YBvfHGkcJa0Z3p7Zyf9zzFLSuiAKv4HY4lbeNLOHIowCXb7gdgLPFdlPOG9xy8gDZtuhJLZ8WwLikzXvK9aEjE4MBpFLQWysRvTcO3BYN8VuRqA9bnmZQQWL8MOf_YEkr_2l7a8zRX6av4K3PKevK2_1yhwrAMhFIzXZbKmnDQwCMA/s4032/IMG_5477.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwkx5r8Kq7YBvfHGkcJa0Z3p7Zyf9zzFLSuiAKv4HY4lbeNLOHIowCXb7gdgLPFdlPOG9xy8gDZtuhJLZ8WwLikzXvK9aEjE4MBpFLQWysRvTcO3BYN8VuRqA9bnmZQQWL8MOf_YEkr_2l7a8zRX6av4K3PKevK2_1yhwrAMhFIzXZbKmnDQwCMA/w400-h300/IMG_5477.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">There are two 'O' rings in the priority valve</span></td></tr></tbody></table><span style="font-family: arial;">I bought mine from a DS parts supplier, but the sizes are given in the parts manuals and you could source your own. Use nitrile for LHM.</span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitbwt1WKd9BUmBgByOHWlzW4-mX-ts5ZSIdFjL40T1pNmuVqrXPh96YpY-BIEQI944oO5514I1cDYbM1DHa4lE6Sg2YGboR_wHvT17HdQA9l_S3rudQuIJnIlxbESFkBe1drtcetMnfN_uwmBU2ATnBhAv7WWKjtYcp__X05fF2RFMVh5bDFGZxg/s1210/1.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="146" data-original-width="1210" height="49" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitbwt1WKd9BUmBgByOHWlzW4-mX-ts5ZSIdFjL40T1pNmuVqrXPh96YpY-BIEQI944oO5514I1cDYbM1DHa4lE6Sg2YGboR_wHvT17HdQA9l_S3rudQuIJnIlxbESFkBe1drtcetMnfN_uwmBU2ATnBhAv7WWKjtYcp__X05fF2RFMVh5bDFGZxg/w400-h49/1.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Seal sizes</span></td></tr></tbody></table></div><p style="font-stretch: normal; line-height: normal; margin: 0px; text-align: justify;"></p><p style="text-align: left;"></p><span style="font-family: arial;"><div style="text-align: justify;">‘Stripdown and rebuild’ is perhaps overdoing it - it does a very clever and important job, but doesn’t have many moving parts to worry about. Perhaps that is why there are no English language instructions for a rebuild in the workshop manuals. It is covered at Operation 453-3 in volume 3 of Manual 583 - but that's in French. The next best I have found is an exploded diagram of a priority valve in the parts manuals. It’s usually just before the diagram that shows the hydraulic reservoir. Here it is from parts manual 562 - which is relevant to the age of my car.</div></span></div>
<p style="font-stretch: normal; line-height: normal; margin: 0px; min-height: 14px; text-align: justify;"></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8VxUW7i0OWsMH14H_EKcgGYQOXcosptnMyZJRUa4EIyEx_Aaq_XVgmWORSkrlrfLYQdCpZG0Jp-YuVCXu75rjeRLEdGbtLd5bh20G3uN35OIg7OrlEzg6Xoyts83pQ-hsK7pmXqPcC9KlE73sfFRGRXe7Dap4AIGralVAmVvEz6PGqb3XkaCNIg/s1183/priority%20valve.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="692" data-original-width="1183" height="234" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8VxUW7i0OWsMH14H_EKcgGYQOXcosptnMyZJRUa4EIyEx_Aaq_XVgmWORSkrlrfLYQdCpZG0Jp-YuVCXu75rjeRLEdGbtLd5bh20G3uN35OIg7OrlEzg6Xoyts83pQ-hsK7pmXqPcC9KlE73sfFRGRXe7Dap4AIGralVAmVvEz6PGqb3XkaCNIg/w400-h234/priority%20valve.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Priority valve - best diagram I could find</span></td></tr></tbody></table><p></p><p style="font-stretch: normal; line-height: normal; margin: 0px; min-height: 14px; text-align: justify;"><span style="font-family: arial;">It’s not exactly the same as what I found inside mine. And that's where that Manual 583 comes in handy.</span></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXAnxlgUnp9FIq4LBHDPSpEoXnDX8s8_HjvNSQShFIE00bNiR2_-obP3zhYaNFDXqYMdTNAP--PqbNgm6ueUZZG_dbqgffKFCMQwZ9R5uQJq3zUm1I02vH0z50_ZPrgSH0_8qMB0zSQuVB3zQfVkQrLYG1cEZxrMeyGu12IXZhFryEkSzjxfTuVg/s782/Priority.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="303" data-original-width="782" height="155" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXAnxlgUnp9FIq4LBHDPSpEoXnDX8s8_HjvNSQShFIE00bNiR2_-obP3zhYaNFDXqYMdTNAP--PqbNgm6ueUZZG_dbqgffKFCMQwZ9R5uQJq3zUm1I02vH0z50_ZPrgSH0_8qMB0zSQuVB3zQfVkQrLYG1cEZxrMeyGu12IXZhFryEkSzjxfTuVg/w400-h155/Priority.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Note the inclusion of part 4.......<br /></span></td></tr></tbody></table><p style="font-stretch: normal; line-height: normal; margin: 0px; min-height: 14px; text-align: justify;"><span style="font-family: arial;">That's more like it. The part numbering is different but Manual 583 correctly shows 11 parts - of which part 4 is the all-important spool valve!</span></p><p style="font-stretch: normal; line-height: normal; margin: 0px; min-height: 14px; text-align: justify;"><br /></p><p style="font-stretch: normal; line-height: normal; margin: 0px; min-height: 14px; text-align: justify;"><span style="font-family: arial;">I started by removing the cap.</span></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4Ilbn1F5iYKa-vJqxx2nffXN0xo3l7wip0kVE3JbdzhkGVG08ijpUchkErhzH6Afjo3Z_b4sUlUDBHMjOIaRNDENCa-T2zuDPtGDTO6gIXrbWWrUEHcdfQTts71oOWdcxHNnFd_NSoyltFzrVoAQdP3Y0C4-gLNzsBk7e9n8-P1odBjjG4AoBhA/s4032/IMG_5317.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4Ilbn1F5iYKa-vJqxx2nffXN0xo3l7wip0kVE3JbdzhkGVG08ijpUchkErhzH6Afjo3Z_b4sUlUDBHMjOIaRNDENCa-T2zuDPtGDTO6gIXrbWWrUEHcdfQTts71oOWdcxHNnFd_NSoyltFzrVoAQdP3Y0C4-gLNzsBk7e9n8-P1odBjjG4AoBhA/w400-h300/IMG_5317.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Removing the cap</span></td></tr></tbody></table><p style="font-stretch: normal; line-height: normal; margin: 0px; min-height: 14px; text-align: justify;"><span style="font-family: arial;">There is an 'O' ring recessed into the body beneath it.</span></p><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhK-qlkU3QkG549BwKrqjrDFoLxQ9LNbJYmpwPfZGQcJ-hWdryLi-Wx6U44wWDPI3u_rYzseYqASKQgktcEK_KlyIYOdClXPZj7waPTtUAVvRjff1LyH03j1cjXYOxyweDn9gHwEXPnJRU7Qqi9j9CHNrc9BCtqRPwJUy6gw-pUoeL4h42PW7_JxQ/s4032/IMG_5318.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhK-qlkU3QkG549BwKrqjrDFoLxQ9LNbJYmpwPfZGQcJ-hWdryLi-Wx6U44wWDPI3u_rYzseYqASKQgktcEK_KlyIYOdClXPZj7waPTtUAVvRjff1LyH03j1cjXYOxyweDn9gHwEXPnJRU7Qqi9j9CHNrc9BCtqRPwJUy6gw-pUoeL4h42PW7_JxQ/w400-h300/IMG_5318.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The first 'O' ring</span></td></tr></tbody></table><span style="font-family: arial;">At the other end I unscrewed the long cover, which revealed the spring.</span></div><div><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPdPpnABUbpKPp4A75nd8S2uRgA7Vd-vjHj1o-wHCxQRTDyvbV12JKdd2e4p1dw7vZ2tHWMsknkgMHU2z10ZiHCakawAVCjhGlQPh-2ZU7bOIsh4B-k13Rp_l6yn-7x_NV6VO0dLwx_GGaveceXRnX2Gti7xYX3WKMjPUbODWpd9t3zzukmMoRtw/s4032/IMG_5319.JPG"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPdPpnABUbpKPp4A75nd8S2uRgA7Vd-vjHj1o-wHCxQRTDyvbV12JKdd2e4p1dw7vZ2tHWMsknkgMHU2z10ZiHCakawAVCjhGlQPh-2ZU7bOIsh4B-k13Rp_l6yn-7x_NV6VO0dLwx_GGaveceXRnX2Gti7xYX3WKMjPUbODWpd9t3zzukmMoRtw/w400-h300/IMG_5319.JPG" width="400" /></a></div><span style="font-family: arial;">Which was covered in black sludge...... Inside the long case (and buried in sludge) was an end piece for the spring - the 'spool stopper'.</span></div><div><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgO-4Kv59g8o63GFdPHAT9ILYLNNPtbsgxLuGfMBnQu0Od3mkz1zyrda91ZQ5OBLJ2vw5rTsQeocrS8nx7fjC43MSvtRm8D7AQoOYOkDsJrAKJezwlSlQ2e8Yjwf8L9PdGQkZ_bHQbSxJ5ESqeezhP_qGdAkKfUOqmYnm87jFRQ8KcyhwtnhLHK5w/s4032/IMG_5320.JPG"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgO-4Kv59g8o63GFdPHAT9ILYLNNPtbsgxLuGfMBnQu0Od3mkz1zyrda91ZQ5OBLJ2vw5rTsQeocrS8nx7fjC43MSvtRm8D7AQoOYOkDsJrAKJezwlSlQ2e8Yjwf8L9PdGQkZ_bHQbSxJ5ESqeezhP_qGdAkKfUOqmYnm87jFRQ8KcyhwtnhLHK5w/w400-h300/IMG_5320.JPG" width="400" /></a></div></div><div><span style="font-family: arial;">There is another 'O' ring in a recess at this end.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaiZdkcuMHwT31soOdvP3NTeQMy31BHiQT1e7sZ1wQPi4G8hXVNlf68shdGMAdCVFnGRNzHIVV4sxi12RIM4B1b32gJXzvZBkeP281bSo1nnHhornj76Q-ZMDIW7FHW2eziHr2GUSq5XX5gSDLgcTHjvc4xik8vm-9tZvfcl9NN1IWvwUj74ZeEA/s4032/IMG_5321.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaiZdkcuMHwT31soOdvP3NTeQMy31BHiQT1e7sZ1wQPi4G8hXVNlf68shdGMAdCVFnGRNzHIVV4sxi12RIM4B1b32gJXzvZBkeP281bSo1nnHhornj76Q-ZMDIW7FHW2eziHr2GUSq5XX5gSDLgcTHjvc4xik8vm-9tZvfcl9NN1IWvwUj74ZeEA/w400-h300/IMG_5321.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">A second 'O' ring.</span></td></tr></tbody></table></div><div><span style="font-family: arial;">With the spring removed, the spool valve is visible in the main body and can be carefully removed. It's a precision fit and should pull out smoothly - like a plunger. You need to be very careful not to drop and dent this, or scratch it. So don't be tempted to use any abrasive cleaners </span></div><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;">You will find attached to it is the thrust washer. </span><span style="font-family: arial; text-align: justify;">I gave the parts a basic clean. It hadn't been immediately obvious because of the sludge, but there was a shim on the thrust stopper I'd removed earlier. You can see it in the photo below - between the spring and the spool stopper.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXQEjvwf9BTslHCxf_gkNjwFManij6oIR5ousbzzO02xJMAzqY2f1spdNvrXkK_ZRuwHxJuD0E-fvbc8L_ZGamKshdOppFrlT2Li4q9PtbSN8j2PiscKmpc3UT7hY5ttlQUsd1LKvAfZLOFsAVLQtLkE_h8uYnr7payDB-Yf37stjgomHyGYA_eg/s4032/IMG_5323.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXQEjvwf9BTslHCxf_gkNjwFManij6oIR5ousbzzO02xJMAzqY2f1spdNvrXkK_ZRuwHxJuD0E-fvbc8L_ZGamKshdOppFrlT2Li4q9PtbSN8j2PiscKmpc3UT7hY5ttlQUsd1LKvAfZLOFsAVLQtLkE_h8uYnr7payDB-Yf37stjgomHyGYA_eg/w400-h300/IMG_5323.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Nearly there. Lots of black sludge</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The </span><span style="font-family: arial;">number of shims (part 5 in the drawing, part 6 in the photo) inside the priority valve may vary, as their function is to compensate for differences in spring strength by altering the lengths over which they operate, and so standardising it so that all units behave the same. I had just one shim in mine.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Everything was carefully cleaned more thoroughly. I used a wire wheel to clean the outside of the main main body and the end caps. </span><span style="font-family: arial;">I used a cotton bud with LHM to carefully clean the bore of the spool valve. </span><span style="font-family: arial;">Parts were dried with compressed air.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">The thrust washer that goes over the spool valve </span><span style="font-family: arial;">serves to hold the inner end of the spring and so, together with the thrust stopper at the other end, compresses the spring when everything is put back together. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1F9Lg-5Tg8ieW0kZ2mp3S2sznrY5PG6e8Sq14Rwqe2cQAmIV5nrssHxp7XW0VSWBSF0O0fsSR2klB2MSpp-pYTqEtK-i0Km0I0bAXXjPSY1gojO6nJeZpzzCIBoIYIgMJQ2WxuS1BphJrZmXq97RjsVVHz3MXxMY3N-DLLO_rQATYlwdqghtAdA/s4032/IMG_5377.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1F9Lg-5Tg8ieW0kZ2mp3S2sznrY5PG6e8Sq14Rwqe2cQAmIV5nrssHxp7XW0VSWBSF0O0fsSR2klB2MSpp-pYTqEtK-i0Km0I0bAXXjPSY1gojO6nJeZpzzCIBoIYIgMJQ2WxuS1BphJrZmXq97RjsVVHz3MXxMY3N-DLLO_rQATYlwdqghtAdA/w400-h300/IMG_5377.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Ready for re-assembly</span></td></tr></tbody></table></div><div><span style="font-family: arial; text-align: justify;">The thrust washer is held in place on the spool valve by a tiny circlip (part 4 in the photo fro manual 583). I left that in place.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6Yh9XLh-w0Hdb1SLOUVtrc7dmGlRimVABuzB1_j6k67MvOPPSNBBdev6exJIu-UvoF-DFci51fkUauzi29FYlnbnejFf8zl0nJYkid576e0oGBCWcW3UwEpGlSoJgv2q-GYP2phKxEkdNL9BaJPY5a_ecnz6IHMQu36IaF_OTO_KIuStEYB6kCg/s4032/IMG_5378%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6Yh9XLh-w0Hdb1SLOUVtrc7dmGlRimVABuzB1_j6k67MvOPPSNBBdev6exJIu-UvoF-DFci51fkUauzi29FYlnbnejFf8zl0nJYkid576e0oGBCWcW3UwEpGlSoJgv2q-GYP2phKxEkdNL9BaJPY5a_ecnz6IHMQu36IaF_OTO_KIuStEYB6kCg/w400-h300/IMG_5378%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Circlip (arrowed) and thrust washer on the spool valve</span></td></tr></tbody></table></div><div><div style="text-align: justify;"><span style="font-family: arial; text-align: left;">On the photo above, note the orientation of the thrust washer, and that it is on the 'long half' of the spool valve. </span></div></div><div><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4jiRIvmRlTiAP5aZvEX1WzfFTbPpXkzutjHe02ajkUWklXpMKohTLfh_M8ZO1io3NyLID7SCafRcY38Uo_UBivuvxItGn68Mf7bgQ4Itjuku3UhTz_xjAvbStnDMnXV0PvygDHdfPvR63PDCUJE-JFQPbyWPPa3tmwB6nUJMB7sV5IKwn7s5qKQ/s4032/IMG_5380.JPG"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4jiRIvmRlTiAP5aZvEX1WzfFTbPpXkzutjHe02ajkUWklXpMKohTLfh_M8ZO1io3NyLID7SCafRcY38Uo_UBivuvxItGn68Mf7bgQ4Itjuku3UhTz_xjAvbStnDMnXV0PvygDHdfPvR63PDCUJE-JFQPbyWPPa3tmwB6nUJMB7sV5IKwn7s5qKQ/w300-h400/IMG_5380.JPG" width="300" /></a></div></div><div><span style="font-family: arial;">The circlip prevents the thrust washer moving the full length of the spool valve......</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEja0ftA84KOMNcTTEAgOOxd_iXutYs6xEObfINrKDVmNTvSJ2OkMkFeck9vQn89ZA25hteqeRaSyuQvyYMxuGm2sSdax0Zs-YumSUANrUNiyZX_m9FAk3XFG9CFVSkdvSDoEnL-ZGG8nCtUPMFDojapnYIrNfAqLZds-3pUrGQkJM0EDkjmbyfDEw/s4032/IMG_5379.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEja0ftA84KOMNcTTEAgOOxd_iXutYs6xEObfINrKDVmNTvSJ2OkMkFeck9vQn89ZA25hteqeRaSyuQvyYMxuGm2sSdax0Zs-YumSUANrUNiyZX_m9FAk3XFG9CFVSkdvSDoEnL-ZGG8nCtUPMFDojapnYIrNfAqLZds-3pUrGQkJM0EDkjmbyfDEw/w300-h400/IMG_5379.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Thrust washer on the spool valve</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">......and so in seeking to expand to it's natural length, the spring pushes against the spool valve.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I brushed some LHM into the valve bore in the body, onto the valve and around the thrust washer before carefully replacing the spool valve in the body. It's the 'short half' that is inserted. It should be a lovely, satisfying smooth fit.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlRC8rFAiahikkztUnqy5O4QyS89BGrCgX8PLAaSHi5aME3So8VgVYBJTR1lrwy0E1UCfwp5yaqwvDjlq3SulxJyq3WyHbsMYf1EYM2N1PfVr5yVYr0tM-RhTNdk-2l9RjD1lsLLmztwoFLKWy-I0MUHoaV4OiKNFPoeohmUH3SGN52aLqasOgxg/s4032/IMG_5382.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlRC8rFAiahikkztUnqy5O4QyS89BGrCgX8PLAaSHi5aME3So8VgVYBJTR1lrwy0E1UCfwp5yaqwvDjlq3SulxJyq3WyHbsMYf1EYM2N1PfVr5yVYr0tM-RhTNdk-2l9RjD1lsLLmztwoFLKWy-I0MUHoaV4OiKNFPoeohmUH3SGN52aLqasOgxg/w400-h300/IMG_5382.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The 'short end' of the spool valve gos in the body</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">A put a little LHM in the recess on the end of the body, and on a new 'O' ring....</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggu3rkenoKMJxU7Mb79YfrSLAFYDrL8ogXFo6bkcl2AJ6buZlr_MFH2wg9Lz1QAAfsYQujYDb2GKyNH9ekW-JRm-CtZtY2poH5hJXwmqFQy8FnauqIgj67WFBVezBpUCZpMMt4dBrBU7ssuM4sq5EI3eAA2PvKim5dkBVm_f1whMcB4Bs7uRgXhQ/s4032/IMG_5384.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggu3rkenoKMJxU7Mb79YfrSLAFYDrL8ogXFo6bkcl2AJ6buZlr_MFH2wg9Lz1QAAfsYQujYDb2GKyNH9ekW-JRm-CtZtY2poH5hJXwmqFQy8FnauqIgj67WFBVezBpUCZpMMt4dBrBU7ssuM4sq5EI3eAA2PvKim5dkBVm_f1whMcB4Bs7uRgXhQ/w400-h300/IMG_5384.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">New 'O' ring</span></td></tr></tbody></table></div><div><span style="font-family: arial;">......</span><span style="font-family: arial; text-align: justify;">before fitting it.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXml_2WRWamzX0IH7A-IzGokutg-Qt0tZWrqEm1Kl9aFq9CYKdtNfVxawxRL5BiZq3xSU8lBsXJIIhT5iT1pHTjm_ihC7bSU8QPNJVcgRh8QUf0gri6rbf9D-UPJ9Nkdm0KzJOafzVIJ9oEfIInTJDQwGwKGdOfXT6fXL_DZMFAEpYoW039uF8ag/s4032/IMG_5385.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXml_2WRWamzX0IH7A-IzGokutg-Qt0tZWrqEm1Kl9aFq9CYKdtNfVxawxRL5BiZq3xSU8lBsXJIIhT5iT1pHTjm_ihC7bSU8QPNJVcgRh8QUf0gri6rbf9D-UPJ9Nkdm0KzJOafzVIJ9oEfIInTJDQwGwKGdOfXT6fXL_DZMFAEpYoW039uF8ag/w400-h300/IMG_5385.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">'O' ring fitted in the recess</span></td></tr></tbody></table><span style="font-family: arial;">Next up were the spring, the shim and the thrust cap. If you look carefully between my fingers in the photo below, you can just see the shim already on the thrust cap.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt4J91emD_tClYll6Vv3OVTgyCx0Tw6K6jKcUYc7rVW46ByjkuJs8bvjo0puvpsBre2gtnW-AZ4X1M23X9q1j1TGVvPHrvf9FesWtce3QsI_JFRV6NYBTHpRgWmWQ9agt1gdp5HORlkfxm5V72qANMNNDVTZSMyjzHFSj-5quV14gHtGgq_3S3Bw/s4032/IMG_5387.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt4J91emD_tClYll6Vv3OVTgyCx0Tw6K6jKcUYc7rVW46ByjkuJs8bvjo0puvpsBre2gtnW-AZ4X1M23X9q1j1TGVvPHrvf9FesWtce3QsI_JFRV6NYBTHpRgWmWQ9agt1gdp5HORlkfxm5V72qANMNNDVTZSMyjzHFSj-5quV14gHtGgq_3S3Bw/w400-h300/IMG_5387.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Thrust cap and shim washer</span></td></tr></tbody></table></div><div><span style="font-family: arial;">I placed on the large end cap and began to screw it home. before I tightened it, I checked that the 'O' ring was correctly seated in it's recessed and would not get pinched by the cap and cause a leak.</span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMeEI_G6hlkv6I2YwK6Ixvrhy17VsnC-I9yPeRH_PQmBoiIkABIDLU2By3hiQhXye3ayjQcBgO3ImhmAAcCWsY74JHaYedH7_mjXwvzeS90_ns7vQ-vFLw5CvnqWjGY5ke2kCYtwTay4GtXneJjY1efx4WpcHEUKcNU9QH6ednYVZzCDbMEzvR_g/s4032/IMG_5390.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMeEI_G6hlkv6I2YwK6Ixvrhy17VsnC-I9yPeRH_PQmBoiIkABIDLU2By3hiQhXye3ayjQcBgO3ImhmAAcCWsY74JHaYedH7_mjXwvzeS90_ns7vQ-vFLw5CvnqWjGY5ke2kCYtwTay4GtXneJjY1efx4WpcHEUKcNU9QH6ednYVZzCDbMEzvR_g/w400-h300/IMG_5390.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Check that the 'O' ring is correctly seated.</span></td></tr></tbody></table><div style="text-align: justify;"><span style="font-family: arial;">The 'O' ring did need re-seating, but that only meant carefully pushing it back down into it's groove with a screwdriver tip.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">The French repair manual 583 says that the cap should be tightened to between 17 and 23 Nm (Newton metres). 1.7 and 2.3 m.kg. (That's about 12.5 to 17 foot lbs.) </span><span style="font-family: arial;">It's not a hex end, so I couldn't use my torque wrench as I don't have any spanner ends for it. It's also very long and even if it did have a hex end, i dong think a long socket would be long enough. Under the circumstances - and with quite a bit of leeway between the recommended torques, i just did it up 'tightly'.......</span></div><p></p>
<div style="text-align: justify;"><span style="font-family: arial;">After lubrication with LHM, the 'O' ring and cap were similarly replaced on the other end. Now this IS a hex end screw, but there are no torque values given for it - so again i just did it up tightly.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8uwNR1WQOSCUIaRYsyyHL7xHpt-hq7hHRP7pQ9JtdAdc96JdF-qnKQWhCloOLkIB3mmzu69uS8T2XpwUywsnVOIQiikfSMSpQvfQ5veO3rpEgECie3uMutxQg0rKBUjzsW95v6D9irapNSYSo1P5nY-D8jvd11o5fwb9S9RnANuba407gwEiiKg/s4032/IMG_5392.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8uwNR1WQOSCUIaRYsyyHL7xHpt-hq7hHRP7pQ9JtdAdc96JdF-qnKQWhCloOLkIB3mmzu69uS8T2XpwUywsnVOIQiikfSMSpQvfQ5veO3rpEgECie3uMutxQg0rKBUjzsW95v6D9irapNSYSo1P5nY-D8jvd11o5fwb9S9RnANuba407gwEiiKg/w400-h300/IMG_5392.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Refitting the second 'O' ring</span></td></tr></tbody></table><span style="font-family: arial;">With everything now back together, I masked off the four hydraulic hose holes and then gave the assembled body a good going over with panel wipe before repainting.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4IlcfXrIatFpION1aOwAWBdS_-QXZ19Bivpm-h8EHKlt9zvm3Bsmh0mYJD3x5sC_MasdI72qFyqb1KWJTJ5dLa3Yvuhs0HKpdj-7eCT9koJgP_utYlrEwFoxbbl2ELDr-V57ml3Oq6-2cXKU7_jSNeCKI7ULmj5J0pZIbM34ux1AeTgWLHw8whg/s4032/IMG_5476.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4IlcfXrIatFpION1aOwAWBdS_-QXZ19Bivpm-h8EHKlt9zvm3Bsmh0mYJD3x5sC_MasdI72qFyqb1KWJTJ5dLa3Yvuhs0HKpdj-7eCT9koJgP_utYlrEwFoxbbl2ELDr-V57ml3Oq6-2cXKU7_jSNeCKI7ULmj5J0pZIbM34ux1AeTgWLHw8whg/w400-h300/IMG_5476.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">'After'</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I have been using BS226 'Brunswick Green' for repainting my hydraulic parts. It looks pretty close to the original. I</span><span style="font-family: arial;">n hindsight I wished I had sprayed some on this part before I stripped it's original paint off and so I could have seen the two colours side-by-side. The truth is that where I have put original Citroen hydraulic parts side-by-side the colours aren't the same anyway! So maybe that's not so much of an issue.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFKaW11TXs1kvVGsHuNaKwE7PxQ2jC1nuCh9mZzIzmIEIB7Ze9bA3MAMeqxBaleTc3KzZ4Ywm_J3SBm5TylRODXzpOlwCS_qfx90zvFEZ8h-omAGnt6dw_oI0vGn2Sm5uvhsoq2MTcuJmBvZEO40snLBt2mgGlVR1gBj4VtfxOWP759kfi16XCFg/s4032/IMG_5315.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFKaW11TXs1kvVGsHuNaKwE7PxQ2jC1nuCh9mZzIzmIEIB7Ze9bA3MAMeqxBaleTc3KzZ4Ywm_J3SBm5TylRODXzpOlwCS_qfx90zvFEZ8h-omAGnt6dw_oI0vGn2Sm5uvhsoq2MTcuJmBvZEO40snLBt2mgGlVR1gBj4VtfxOWP759kfi16XCFg/w400-h300/IMG_5315.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">'Before' </span></td></tr></tbody></table><br /></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-34100804268095831962022-09-19T19:49:00.002+00:002022-09-29T21:27:00.930+00:00Replacing the Nylon Fuel Line<div style="text-align: left;"><span style="font-family: arial;">I've put in a new fuel line.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyvpzYHqgrE8XTlaUjLO-L4-YakPAmIhYGMEXCgAzgPyiLCNTSGv9R2yI1P_Tg7e-N8O62ivS3YOoMCv8_35A9recwnVgb27LUPDndguxi3QQ3SQz8Qt0ja2o3T4IAlNCNfWvHbxf4GWeqNoZ-_JHiOUMDJbSFRrzu9PrDScjg1tEQ4XaICUPW1A/s4032/IMG_5421.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyvpzYHqgrE8XTlaUjLO-L4-YakPAmIhYGMEXCgAzgPyiLCNTSGv9R2yI1P_Tg7e-N8O62ivS3YOoMCv8_35A9recwnVgb27LUPDndguxi3QQ3SQz8Qt0ja2o3T4IAlNCNfWvHbxf4GWeqNoZ-_JHiOUMDJbSFRrzu9PrDScjg1tEQ4XaICUPW1A/w400-h300/IMG_5421.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">New fuel line in the engine bay</span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial; text-align: justify;">In anticipation of replacing the outer sills, I'd stripped out from the left hand sill, the wiring loom to the rear, the control rod for the rear height corrector (you can read about that </span><a href="https://ds-restoration.blogspot.com/2021/08/inside-every-small-job.html" style="font-family: arial; text-align: justify;" target="_blank">HERE</a><span style="font-family: arial; text-align: justify;">) and the thin rilsan return hose from the rear to the reservoir. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOMR9qR__ln6Lm2OCSXA5BTPNuGD3LUpq9fAHaBV_FfY41yEsynvgC54k1NT3pwqT4IWllkf74Iw7AAuc2xLbEzcZKV3k53jiUFM62NzDe6Omp0rq6-Ub6RSoDIN5RrQWjy0cb3APKkpSqckBqyqcnIKJohSxznrUVk54ll3gXqinAL1GJt2iHCA/s3264/IMG_9966%20copy2.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOMR9qR__ln6Lm2OCSXA5BTPNuGD3LUpq9fAHaBV_FfY41yEsynvgC54k1NT3pwqT4IWllkf74Iw7AAuc2xLbEzcZKV3k53jiUFM62NzDe6Omp0rq6-Ub6RSoDIN5RrQWjy0cb3APKkpSqckBqyqcnIKJohSxznrUVk54ll3gXqinAL1GJt2iHCA/w300-h400/IMG_9966%20copy2.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Height corrector rod under the sill</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I left in place the run of four hydraulic pipes as mine had no joins in the middle and so were not easily removed.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiz88nJRJgwqRWAR-JRZvD1IWBdRyeQOzkd4RNTr_vpj-vqDzG25_0WjqfEksVJNYK9AlQU6SJZZ-PgLGbXmumCmWdZ9ICDYB0eRNmnDy1yHteg--XVoomLPD6cS_yCTaZ4EJa8ItHIINEWezVX2Xd4_wz-leLFVPfwu8iqSvwC7QWL3gDIJ993Iw/s3264/IMG_0980.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiz88nJRJgwqRWAR-JRZvD1IWBdRyeQOzkd4RNTr_vpj-vqDzG25_0WjqfEksVJNYK9AlQU6SJZZ-PgLGbXmumCmWdZ9ICDYB0eRNmnDy1yHteg--XVoomLPD6cS_yCTaZ4EJa8ItHIINEWezVX2Xd4_wz-leLFVPfwu8iqSvwC7QWL3gDIJ993Iw/w400-h300/IMG_0980.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Hydraulic pipes under the left hand sill</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">From the right hand sill I'd loosened the nylon fuel line and the rilsan return hose to the reservoir. I'd undone the brackets that secure the pipe to the face of the sill but it still passed through the bottom of the 'B' pillar. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSl1vCB8mF-VECwPxfsFCL68s4UMZ7icTfyRB43GskkBzaqTP6bozEChi7g9GlQJIjUjcSOJ-StoWPsB0Xdiem52lwjZLo7roLlT-aXQo42U7ViJ-xbjKyH0cPnqaTVtMHkdexOAUFSc9nvvKkltz-tkrB2f2le4duU-bsoDRfsxBgJXmK4cpVfQ/s3264/IMG_9977%20copy.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="2448" data-original-width="3264" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSl1vCB8mF-VECwPxfsFCL68s4UMZ7icTfyRB43GskkBzaqTP6bozEChi7g9GlQJIjUjcSOJ-StoWPsB0Xdiem52lwjZLo7roLlT-aXQo42U7ViJ-xbjKyH0cPnqaTVtMHkdexOAUFSc9nvvKkltz-tkrB2f2le4duU-bsoDRfsxBgJXmK4cpVfQ/w400-h300/IMG_9977%20copy.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Fuel line passing through the base of the 'B' post</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">In removing the fuel tank and pulling the old and stiffened fuel line out from the tank and through the sill, the fuel line had suddenly 'bowed' between the sill hole and the 'B' pillar........and suddenly folded on itself.</span><span style="font-family: arial;"> </span><span style="font-family: arial;">I couldn't see any obvious damage but I'd read that this can be fatal as the pipe may then leak when refitted. So I decided not to take the chance and to replace it.</span></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><span style="font-family: arial;">At the front end of the car the fuel line passes behind the right hand side suspension unit.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEgwYmEwlaDiEOcqt7Eyzw0uF6KezwsCP_Ej7v791dfxnoYFV38ll3wOrFp366X1FXRHhkDdg6YIsehw4ENBtrEwU-9ufFPJlmE6q1FEJe0h_z49ULKQvR48p0x11iz0LM0o_Z26wcWvXfj2D-jckDhQ9Oo-FbJF43otUvzkKi28gE64SWmBuEAA/s4032/IMG_3967%20copy.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEgwYmEwlaDiEOcqt7Eyzw0uF6KezwsCP_Ej7v791dfxnoYFV38ll3wOrFp366X1FXRHhkDdg6YIsehw4ENBtrEwU-9ufFPJlmE6q1FEJe0h_z49ULKQvR48p0x11iz0LM0o_Z26wcWvXfj2D-jckDhQ9Oo-FbJF43otUvzkKi28gE64SWmBuEAA/w400-h300/IMG_3967%20copy.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The fuel line and return pipe pass behind the suspension</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">So before I could refit the suspension arm I needed to refit the fuel line....I understand that efi cars have a fuel pump hidden in the sill - so presumably the fuel line is at least two pieces. On a carburettor car, the fuel line is one continuous length - from the bottom of the fuel filter in the tank, to a short rubber section that joins to it the fuel pump on the side of the block. The replacement fuel line I bought is 5 metres long. </span></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><span style="font-family: arial;">Where they pass behind the front jacking point, the fuel line and return hose are held in a long thin carrier bracket - held in place by a single bolt in the wheel arch. </span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiegeOGFpi5d-dQnzdAa6yjOlAjBqHtJruk2ICoQoNEMc6uuhSE7xHt_QnFJG6WZG_GmE_JqZmjrXghEUGXvEBmDYhcQClBWvzHqPrr_e9GIYyFAghcy4nhEFuGE9qhUFZPvQnApQO74lMXfaUf4uUzw_jHwCxYo8PblLQjIcLzmGnPcRRJl66wxQ/s4032/IMG_3970%20copy.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiegeOGFpi5d-dQnzdAa6yjOlAjBqHtJruk2ICoQoNEMc6uuhSE7xHt_QnFJG6WZG_GmE_JqZmjrXghEUGXvEBmDYhcQClBWvzHqPrr_e9GIYyFAghcy4nhEFuGE9qhUFZPvQnApQO74lMXfaUf4uUzw_jHwCxYo8PblLQjIcLzmGnPcRRJl66wxQ/w400-h300/IMG_3970%20copy.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Bolt holding the carrier bracket</span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial;">This is unbolted and pulled out towards the front of the car. Provided all the other little brackets along the length of the sill have been undone, and the black rubber 'pipe' connector on the rear end has been disconnected.......</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgObBnOBVnDhzmdZvIP1ukoPIZsAF5QqBXnY1VCAunUvrfnNaFGsR62Z3j62bqU7v66-2TudKi1AFDNsKrK2IdmXlNl2FXoA3N158NNSYyxLvLB6_aqn56F2Opb5QgdIT0XML8-4tNIG3zeRfgyLO40stslaMhcFHXbv70G-RAaW62tAUMhlRzG1A/s4032/IMG_5283.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgObBnOBVnDhzmdZvIP1ukoPIZsAF5QqBXnY1VCAunUvrfnNaFGsR62Z3j62bqU7v66-2TudKi1AFDNsKrK2IdmXlNl2FXoA3N158NNSYyxLvLB6_aqn56F2Opb5QgdIT0XML8-4tNIG3zeRfgyLO40stslaMhcFHXbv70G-RAaW62tAUMhlRzG1A/w400-h300/IMG_5283.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The return pipe on the erm....'pipe'......</span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial;">.....the pair of lines should pull right out.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjPvHMqrrV9NNKfcYmNVbwNI5eVi9Pokg_DaLLGUSzwLHJocAAcNM-0J8UJH2g5MtPqi-fNvg6zIv0p5gJQl9ulu6lxEiWEjTSHBZ0V70AOyf-ZokSZJwNGlgDOBX1fVOBicnkOgI_TBGko-giS_mywdRCQ_Q9aQs7E5JJUMssbBeMyf-KFMRGtQ/s4032/IMG_5234.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjPvHMqrrV9NNKfcYmNVbwNI5eVi9Pokg_DaLLGUSzwLHJocAAcNM-0J8UJH2g5MtPqi-fNvg6zIv0p5gJQl9ulu6lxEiWEjTSHBZ0V70AOyf-ZokSZJwNGlgDOBX1fVOBicnkOgI_TBGko-giS_mywdRCQ_Q9aQs7E5JJUMssbBeMyf-KFMRGtQ/w300-h400/IMG_5234.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Fuel line removed....</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial; text-align: left;">The bracket fingers were surprisingly hard to open. Within each one was a rubber collar. The bracket got a coat of paint and the the collars got a clean.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><div style="font-family: -webkit-standard; text-align: left;"><span style="font-family: arial;"><div style="font-family: -webkit-standard;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgykw_QoYVGK2_Wb9I7Dh1EHuYhNO57k8g8Uo9P_gfs0vna8s79g2L7cMN2rL_GvtSBvI8-4ihVxjeAyy5hwJlJkiL7GH_DGQbjM8uKdc5ZpkJp9CM8dRtDVImhoWbzea5TuF96QbI3FWK26IZ_scCfTcT0px5S6gWQpn9gocIWJO3GzkhOSU0xSA/s4032/IMG_5258.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgykw_QoYVGK2_Wb9I7Dh1EHuYhNO57k8g8Uo9P_gfs0vna8s79g2L7cMN2rL_GvtSBvI8-4ihVxjeAyy5hwJlJkiL7GH_DGQbjM8uKdc5ZpkJp9CM8dRtDVImhoWbzea5TuF96QbI3FWK26IZ_scCfTcT0px5S6gWQpn9gocIWJO3GzkhOSU0xSA/w400-h300/IMG_5258.JPG" width="400" /></a></div></div></span></div></span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">The new fuel line was coiled and springy and I grappled with it on the garage floor. Lining up the new fuel line to the old I worked out approximately where the bracket needed to be fitted on the new line - allowing excess hose at both ends for final adjustment when fitted.</span></div><div style="text-align: left;"><span style="font-family: arial;"><div style="font-family: -webkit-standard;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKcYEqHl6yqXxnwnUz_2SGT3LWS1ayFAkIFlwgDwLBxySHU_c59dXnt6mhVMgTIkth76AQ2ZTeh9uZBSYqVE_3zRIaHWbiaxxNt5z7mhFVfnE1G1sO5_akCDxY8qkSLD3kiy2H5HclehOXpwQS4ctXkWuqbsm19MSVjtEVNZ8v-wU9wACoITmXQA/s4032/IMG_5284.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKcYEqHl6yqXxnwnUz_2SGT3LWS1ayFAkIFlwgDwLBxySHU_c59dXnt6mhVMgTIkth76AQ2ZTeh9uZBSYqVE_3zRIaHWbiaxxNt5z7mhFVfnE1G1sO5_akCDxY8qkSLD3kiy2H5HclehOXpwQS4ctXkWuqbsm19MSVjtEVNZ8v-wU9wACoITmXQA/w400-h300/IMG_5284.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">New fuel line and carrier bracket</span></td></tr></tbody></table></div><div style="font-family: -webkit-standard;"><span style="font-family: arial;">The fuel line follows quite a twisty route and it was not until I'd crimped it back in the bracket that I could do a trial fit. The fuel line goes in the top row of clips on the bracket.</span></div></span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtwoscSBsOZKmAoMuwT3CPSy3eGJr-6tL7eHn1jbxhopQcZjndY_BjrMYVDCWF_70TrQIdyjbxppfT9gSwEy8u5-2U7kUWqtZ0Co0RPK6HclKLLFUmWFUOcUtTRn9SZsl74iT3jjfE98CA3qKzCnD5HbUZ_GP6VYjYbKzFoPRvLlZeejFBtI74Rg/s4032/IMG_5260.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtwoscSBsOZKmAoMuwT3CPSy3eGJr-6tL7eHn1jbxhopQcZjndY_BjrMYVDCWF_70TrQIdyjbxppfT9gSwEy8u5-2U7kUWqtZ0Co0RPK6HclKLLFUmWFUOcUtTRn9SZsl74iT3jjfE98CA3qKzCnD5HbUZ_GP6VYjYbKzFoPRvLlZeejFBtI74Rg/w400-h300/IMG_5260.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Fuel line removed from the carrier bracket</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><span style="text-align: left;">The carrier bracket is slid into the hole in the wheel arch and bolted down. </span>When refitting the black 'pipe' I though the return hose felt a bit loose and couldn't remember what it had been like when I first pulled it off. If it leaked, it would be hidden away behind the jacking point. Although it didn't look as though it originally had a collar around the thin end, I put a Ligarex band around the thin end to reduce the risk of leakage, and I replaced the clip on the fat end with a Mirex buckle.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSfqgeE1mCsKueHkWwI7fA4krOH3j90k8YdJxsVhiZnQtjm38otVObAFyDyTAG8l38htHDzS8nLC0ITnaIyy_rVjdVjycggu6exejQsNr_2ulj_T9Nn0D1U3Tx0Nv8p2Ffi_Hg9hnkENZyHREdAGUZUWb7JmC2mE04I_Nr5oTIqsJHZP0acNaYqA/s4032/IMG_5427.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSfqgeE1mCsKueHkWwI7fA4krOH3j90k8YdJxsVhiZnQtjm38otVObAFyDyTAG8l38htHDzS8nLC0ITnaIyy_rVjdVjycggu6exejQsNr_2ulj_T9Nn0D1U3Tx0Nv8p2Ffi_Hg9hnkENZyHREdAGUZUWb7JmC2mE04I_Nr5oTIqsJHZP0acNaYqA/w400-h300/IMG_5427.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Mirex buckle on the 'pipe'</span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial;">Starting forward from the bracket, the fuel line goes up into the wheel arch corner where the suspension cylinder sits, before coming forward in the wheel arch.....</span></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjd9c_Uoc-Wd0bMrKA9JgCit7HfAsnwaPu94iNBVDkRY7GvNaTOWRzHIs7JAJ_P21KBdeGPfU1ded8MKB3tuPn87bJzRy5X6xFjexlvCIwAr-fewu5F9ZYT7SxtRjluZFEBy4KSyG6erSw_4L0cFnpKmGQuwFE1gSlR96YemuMO8JY1h_vkbYMxbw/s4032/IMG_5285.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjd9c_Uoc-Wd0bMrKA9JgCit7HfAsnwaPu94iNBVDkRY7GvNaTOWRzHIs7JAJ_P21KBdeGPfU1ded8MKB3tuPn87bJzRy5X6xFjexlvCIwAr-fewu5F9ZYT7SxtRjluZFEBy4KSyG6erSw_4L0cFnpKmGQuwFE1gSlR96YemuMO8JY1h_vkbYMxbw/w400-h300/IMG_5285.JPG" width="400" /></a></div><div style="text-align: left;"><span style="font-family: arial;"> ........and it then</span><span style="font-family: arial;"> ducks down - held by a bracket - behind the suspension unit. </span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUvnKE3prGy-XYZ36reIQs5kjipAMsP4liz_GghXqypQpEUgi4cGplUVmRkkzoO4rpD4BoQ8u7OMtHVG6CZSgImvf9zjPKvTg5E8WkNXE9TOosnQkAWUoTA7UU57pDfrvCqr73Nri8g2xSqhBmz0tLx3ZZU4CxSCaIuRJCSWgkJ67Y4xiQS-aI5w/s4032/IMG_5438.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUvnKE3prGy-XYZ36reIQs5kjipAMsP4liz_GghXqypQpEUgi4cGplUVmRkkzoO4rpD4BoQ8u7OMtHVG6CZSgImvf9zjPKvTg5E8WkNXE9TOosnQkAWUoTA7UU57pDfrvCqr73Nri8g2xSqhBmz0tLx3ZZU4CxSCaIuRJCSWgkJ67Y4xiQS-aI5w/w400-h300/IMG_5438.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The fuel line passes behind the suspension unit</span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial;">From there it runs under the hollow of the beam across the engine bay.....</span></div><div style="text-align: left;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjc8ucy9R3LK6P-m_IR2FNeDkx8B0GiqSa-RYMIn49CFuI84nx39B60ilTMqgkCsj6gKCxY7jykWfwlZ5Z-ZuVtK5FCBmWcKpzmLOds2RFkqNwbpiZYBXwtj3vOO-WyDYZgh_RxNcGHeoW1bs18H74y85Y6dhL1dZSkJiy7RraRmsO3jmbVejIsFQ/s4032/IMG_5422.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjc8ucy9R3LK6P-m_IR2FNeDkx8B0GiqSa-RYMIn49CFuI84nx39B60ilTMqgkCsj6gKCxY7jykWfwlZ5Z-ZuVtK5FCBmWcKpzmLOds2RFkqNwbpiZYBXwtj3vOO-WyDYZgh_RxNcGHeoW1bs18H74y85Y6dhL1dZSkJiy7RraRmsO3jmbVejIsFQ/w400-h300/IMG_5422.JPG" width="400" /></a></div></div><div style="text-align: left;"><div class="separator" style="clear: both; text-align: center;"><br /></div></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdvjRBDEo1R7KiuFVPNcvDb0R1HFzrnpcSkC8NI3tT_gSUSEWdVoc3hrCei_66AnFjvDdhW4G0juFJl_nGO-mI1s2tSKm0qfNrDq9jd54_q1knetfCkKvgSdQqzwclcqd4l_FwZXWgYPFtdFUpl0h--Yz7EadEYT5TAA-TvzvqbSIh0bd2Hpbpwg/s4032/IMG_5424.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdvjRBDEo1R7KiuFVPNcvDb0R1HFzrnpcSkC8NI3tT_gSUSEWdVoc3hrCei_66AnFjvDdhW4G0juFJl_nGO-mI1s2tSKm0qfNrDq9jd54_q1knetfCkKvgSdQqzwclcqd4l_FwZXWgYPFtdFUpl0h--Yz7EadEYT5TAA-TvzvqbSIh0bd2Hpbpwg/w400-h300/IMG_5424.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Fuel line running under the cross beam</span></td></tr></tbody></table><div style="text-align: left;"><span style="font-family: arial;">......and emerges through a hole in that beam. </span><span style="font-family: arial; text-align: justify;">The hole is lined with a grommet to stop the fuel line rubbing and wearing. I had a spare grommet for the where the hydraulic hose pass through the radiator bracket and it was just the right size for this particular job. I put some tape over the end of the pipe but otherwise left it loose in the engine bay.</span></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><span style="font-family: arial;">Going backwards from the bracket by the jacking point, the pipes emerge under the front door hinges.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgigBUjnLwpqoH7AhrkBPGwvoMZc8NSyhedh3vt1TR2ziwuRV05scQEAmTTYiMbBBf9Aa3eD6tcEfFEOyd0VLY-TPSyAbx2OeQJ7cTXoDfbBpxYxgN7CxqRCLqGU1Y731wN3hsTO-S7E7a6HOjnZfpH4NXjIfQKpD-zgRrvoLF61bQU9lBUQ--DWw/s4032/IMG_5426.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgigBUjnLwpqoH7AhrkBPGwvoMZc8NSyhedh3vt1TR2ziwuRV05scQEAmTTYiMbBBf9Aa3eD6tcEfFEOyd0VLY-TPSyAbx2OeQJ7cTXoDfbBpxYxgN7CxqRCLqGU1Y731wN3hsTO-S7E7a6HOjnZfpH4NXjIfQKpD-zgRrvoLF61bQU9lBUQ--DWw/w400-h300/IMG_5426.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Pipes behind the jacking point</span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial;">From there, the fuel line and return line run along the sill......</span></div><div style="text-align: left;"><span style="font-family: arial;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="font-family: -webkit-standard; margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOJHc5t6QBjyIak1vIsYyIP87Voi3KLzwNaWFpjwPwQ0FB383lM5VOjaAgRhY12Z17lzO6CiE0dOuPKTNjyR68NUtt3E5Vh6ozzP74MGSxr6W2JtN1-fFTBsI2taseVjL-YWDMCvB5j7FaCwoTJDoWJQoXoZZR6r1vA1zq7iBuxIi7iwA-MjjwwQ/s4032/IMG_5287.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOJHc5t6QBjyIak1vIsYyIP87Voi3KLzwNaWFpjwPwQ0FB383lM5VOjaAgRhY12Z17lzO6CiE0dOuPKTNjyR68NUtt3E5Vh6ozzP74MGSxr6W2JtN1-fFTBsI2taseVjL-YWDMCvB5j7FaCwoTJDoWJQoXoZZR6r1vA1zq7iBuxIi7iwA-MjjwwQ/w400-h300/IMG_5287.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><br /></td></tr></tbody></table></span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg16zPOQsgn4D8iqQHUh66rYWmKuMi88inOCdJ1Hml1zVSvcnaHSG7c9LRwcUYUivHUa1UELxeH57KEHyhcDLUHFxXAQ5L_XP7UFiMHXjJ2CIK1Q88xeRsS-Hl-3d4PW9eEDhnWapEcjGwPKEPwq6CrjlsCXLH3bUTL-sMmQcGDf-vtmkNLmvHDyA/s4032/IMG_5289.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg16zPOQsgn4D8iqQHUh66rYWmKuMi88inOCdJ1Hml1zVSvcnaHSG7c9LRwcUYUivHUa1UELxeH57KEHyhcDLUHFxXAQ5L_XP7UFiMHXjJ2CIK1Q88xeRsS-Hl-3d4PW9eEDhnWapEcjGwPKEPwq6CrjlsCXLH3bUTL-sMmQcGDf-vtmkNLmvHDyA/w400-h300/IMG_5289.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The pipes running past the jacking peg</span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial;">.......and towards the base of the 'B' post.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmDkVghTEK-G-_fdfBTcEXUtLgEA844-oiR7MbSVh2mCo6TvqWegmm7dGEX6cUkyHmv1f_HNqTU-2VS2YX3FWxcWmXUlh2KNkMlW4rlRiEQVFfCX2de4aIkxGgf9MISEQxqc4Ai7C-OgLItS_E-dgxpPf9hPTt8NSbbC43eiCzf5PIvdTBhVoi1g/s4032/IMG_5290.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmDkVghTEK-G-_fdfBTcEXUtLgEA844-oiR7MbSVh2mCo6TvqWegmm7dGEX6cUkyHmv1f_HNqTU-2VS2YX3FWxcWmXUlh2KNkMlW4rlRiEQVFfCX2de4aIkxGgf9MISEQxqc4Ai7C-OgLItS_E-dgxpPf9hPTt8NSbbC43eiCzf5PIvdTBhVoi1g/w400-h300/IMG_5290.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Pipes at the 'B' post</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Along that route, there are several 'm' shaped double pipe clips and rubber collars to hold the hoses in place. These screw into nuts welded inside the sealed box section.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">After the 'B' post the two hoses go their separate ways. The return hose continues to the back end of the sill - supported by a couple of single pipe clips and joins another black rubber 'pipe' in the rear wheel arch. I've not joined it back up yet as I anticipate doing further work in the rear wheel arches.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxwBuMCd3w31M4wRvtyR7BmFdtSAjjPDprdXuiSneiUJfezBhzBt-F-zdZebihlSMjDQgvPWG9jQW2KxbVY8l-Iy3eby1MP7-e67eb9IiPVOrqXIhEpChrpjCKy8_7kBRtE7_lKWtbeZgLpiPaVBqUsGO4zdKmxaFYPZe_cNkRcBR0dT1Nwx__zw/s4032/IMG_5292.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxwBuMCd3w31M4wRvtyR7BmFdtSAjjPDprdXuiSneiUJfezBhzBt-F-zdZebihlSMjDQgvPWG9jQW2KxbVY8l-Iy3eby1MP7-e67eb9IiPVOrqXIhEpChrpjCKy8_7kBRtE7_lKWtbeZgLpiPaVBqUsGO4zdKmxaFYPZe_cNkRcBR0dT1Nwx__zw/w300-h400/IMG_5292.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The return pipe extends to the end of the sill</span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial;">The fuel line branches off and passes through two offset holes in the sill to end up in the fuel tank gap - under the rear seat. There are grommets to line the holes.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwjawXofvsYxpehR0ciDGJh1htySKecEyuHiUQdOVXTjwFVjx-r0baS3TcefZXe-ZAYJMIpfv3B2CndPOEF8_QshwpW79xz249kYOUsBsfdc2ll_eEPPD1nhmkPRV7WqG5z0rtqaHo9a0mXEnzhsEDFnEehEnxt7m4UP2k_8mB3UGOwKlJXhKEkg/s3264/IMG_0942%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3264" data-original-width="2448" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwjawXofvsYxpehR0ciDGJh1htySKecEyuHiUQdOVXTjwFVjx-r0baS3TcefZXe-ZAYJMIpfv3B2CndPOEF8_QshwpW79xz249kYOUsBsfdc2ll_eEPPD1nhmkPRV7WqG5z0rtqaHo9a0mXEnzhsEDFnEehEnxt7m4UP2k_8mB3UGOwKlJXhKEkg/w300-h400/IMG_0942%20copy.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Fuel line to the fuel tank</span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial;">When I refit the fuel tank i will need to manoeuvre the fuel line again and I will need to be careful not to kink it again. For that reason I've only temporarily fitted the brackets under the sill at the back end of the car. I will need to make sure that I cut the line long enough so that it sits at the very bottom of the fuel stack and doesn't ride up. I will probably cut and fit the rear end first and then adjust the positioning back towards the front. I've allowed plenty of spare at both ends at the moment.</span></div><div style="text-align: left;"><br /></div><div style="text-align: left;"><span style="font-family: arial;">There is also an outer sealing sleeve over the fuel line where it joins the tank. I will put a couple of Ligarex straps around the ends of this to make sure they are airtight and help the pump maintain suction.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEji3fHCBSg4EQJ7PMKur-Cv7zG-J00cXsZOso9nrO7qkPpW4Bvb10f8kxd6tgbrm9uy_dipbe_DdLNyRZ7y9FdA0JmnqKw7wIS0ZZOVcRRM9O15dpt1uA3nkgy3cOlBb4lhQFphazgV4vtHPX57pXUg5m4Pe0Y8wTS2NWTQufbexESlq9hTSRAIew/s4032/IMG_5428.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEji3fHCBSg4EQJ7PMKur-Cv7zG-J00cXsZOso9nrO7qkPpW4Bvb10f8kxd6tgbrm9uy_dipbe_DdLNyRZ7y9FdA0JmnqKw7wIS0ZZOVcRRM9O15dpt1uA3nkgy3cOlBb4lhQFphazgV4vtHPX57pXUg5m4Pe0Y8wTS2NWTQufbexESlq9hTSRAIew/w400-h300/IMG_5428.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Sealing sleeve over the tank end of the fuel line</span></td></tr></tbody></table></div><div style="text-align: left;"><div class="separator" style="clear: both; text-align: justify;"><br /></div><div class="separator" style="clear: both; text-align: justify;"><span style="font-family: arial; text-align: left;"><b>Left hand Sill</b></span></div><div class="separator" style="clear: both; text-align: justify;"><span style="font-family: arial; text-align: left;">I did similar work under the left hand sill. I refitted the long control rod for the rear height corrector - with it's replaced threaded end. I cleaned and replaced the nylon eyelets in the clips along sill that guide the rod. There are four eyelets and only three clips. the fourth eyelet goes in a hole in the 'B' post. </span><span style="font-family: arial; text-align: left;">The rod first pushes into the footwell from the wheel arch, and then needs to duck down (where the height lever would be) into the sill and out into the opening beneath. At first it was tricky to get the rod to flex enough to go into the sill but once it started it slid smoothly and was easily guided through the eyelets - which i greased in advance. </span></div></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEsPT_cC4taO13jk0UHnNzhyS3kUycoaVvCFlBX616rBr-6S2f9-QtRe4IMrhuI2yuzT5ew-nPv6y7Kt4sFQm4f_tEL8y43MFCw2tg-0tpSOUHPA3T8cne4y7vYHRq65N9UxTiefNsjSaLMhBqtqpxas5KUR_h1ProFQWvV5u_3qkw7qy08F-zIw/s4032/IMG_5437.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEsPT_cC4taO13jk0UHnNzhyS3kUycoaVvCFlBX616rBr-6S2f9-QtRe4IMrhuI2yuzT5ew-nPv6y7Kt4sFQm4f_tEL8y43MFCw2tg-0tpSOUHPA3T8cne4y7vYHRq65N9UxTiefNsjSaLMhBqtqpxas5KUR_h1ProFQWvV5u_3qkw7qy08F-zIw/w400-h300/IMG_5437.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Eyelet for the height corrector link rod</span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial; text-align: justify;">My friend Peter had made a new knuckle for the end. I liberally coated threads and knuckle with grease - to prevent the rusting problems that caused it to snap on removal - and I temporarily put a split pin through the linkage. I will need to adjust the linkage once the hydraulics are rebuilt.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilJpP7vwvctMlJeHeIRKXMxho579u0wAGvyV8JtrAC1Hplm5N9E9TAs0uMEuFecRvPLMGz5UKhwrfrEduKuKIzSJWKVyerO4Jz_20TSq8w1tBT-C2g66K9cFqhJOZJfJPb4JLQyJmo8zt7oiCsh_Ld2okkWBaU__E1kG-_EgfAkKs9LW2PZSPANg/s4032/IMG_5431.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilJpP7vwvctMlJeHeIRKXMxho579u0wAGvyV8JtrAC1Hplm5N9E9TAs0uMEuFecRvPLMGz5UKhwrfrEduKuKIzSJWKVyerO4Jz_20TSq8w1tBT-C2g66K9cFqhJOZJfJPb4JLQyJmo8zt7oiCsh_Ld2okkWBaU__E1kG-_EgfAkKs9LW2PZSPANg/w400-h300/IMG_5431.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Rear height corrector linkage - temporary connection</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">At the front jacking point, the thin rilsan return pipe was attached to an old offcut of hydraulic pipe and (eventually) threaded forward, from behind the jacking point, and out into the wheel arch. It's held in place along the sill by a few arrow-headed rubber straps that join it to the run of hydraulic pipes.</span></div><div style="text-align: left;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwinxXrBFlPgBMG30SW1cl7yOIl6rsvMtFCEDEWbS-9mLlCeRisi6lQfNLToxkwwL0pp0gpNk9OSyoGPCQYVXLeK3E6jz21ryFVncAEoZa7sL3Ns9uJJ5uqKjPl5WBeoOS0jFdvwQLrQVoFKsugc-igRDQEEPENzoPc7rkl1kTlhK5-53Lp2jHAg/s4032/IMG_5434.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwinxXrBFlPgBMG30SW1cl7yOIl6rsvMtFCEDEWbS-9mLlCeRisi6lQfNLToxkwwL0pp0gpNk9OSyoGPCQYVXLeK3E6jz21ryFVncAEoZa7sL3Ns9uJJ5uqKjPl5WBeoOS0jFdvwQLrQVoFKsugc-igRDQEEPENzoPc7rkl1kTlhK5-53Lp2jHAg/w300-h400/IMG_5434.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Rilsan tube behind the jacking point</span></td></tr></tbody></table></div><div style="text-align: left;"><span style="font-family: arial;">At this point i haven't refitted the rear wiring loom in the left hand sill. I will probably do that when I fit the new main loom behind the dashboard.</span></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com5tag:blogger.com,1999:blog-4597517440111518822.post-89625044653147891282022-09-12T19:14:00.013+00:002023-02-04T15:57:55.992+00:00Front Suspension Units - Replacing The Bearings<div><span style="font-family: arial;">I've completed the work to replace the bearings in the front suspension arms. It was a bit of a saga.......</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVpL1MQnTUSLf7BYHeH3tBytP63b-fSIpCETU3y8uGyMuZazlWeb_aZP_XIfygXcpINGYygpr6EGEsnuPapmZbM1D-9WBIUUaiICqJfLGHnJjffdl6ciJZHFZkYD33QxEvf-PJJu-txh2cGXeM3yeZZI-HYxeYoflO3_qa3E0sDFoQ-hAvR1CLjA/s4032/IMG_3115.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVpL1MQnTUSLf7BYHeH3tBytP63b-fSIpCETU3y8uGyMuZazlWeb_aZP_XIfygXcpINGYygpr6EGEsnuPapmZbM1D-9WBIUUaiICqJfLGHnJjffdl6ciJZHFZkYD33QxEvf-PJJu-txh2cGXeM3yeZZI-HYxeYoflO3_qa3E0sDFoQ-hAvR1CLjA/w400-h300/IMG_3115.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">'New old stock' suspension am bearings</span></td></tr></tbody></table></div><div><span style="text-align: justify;"><span style="font-family: arial;">I'd removed the front suspension units back in mid 2021. You can read about that <a href="https://ds-restoration.blogspot.com/2021/05/anti-roll-bar-and-half-axle-removal.html" target="_blank">HERE</a>. </span></span></div><div><span style="text-align: justify;"><span style="font-family: arial;"><br /></span></span></div><div><span style="text-align: justify;"><span style="font-family: arial;">With the weight of the wheel hubs removed I could move the arms independently to see how they felt. They felt a bit 'notchy' but not too bad. Others have reported very stiff arms - which cannot be good for the 'magic carpet' ride of a DS. The problem is that the arms do not rotate through much of an arc, so even though the surfaces are hardened, the bearing rollers tend to wear just a small area of the arm - eventually creating grooves which prevent the bearing rollers moving freely and causing stiffness. I think this is through 'brinelling' - which seems to be where excessive pressure in a small area causes a permanent indentation in a hardened surface. </span></span><span style="font-family: arial; text-align: justify;">Lack of grease, or the ingress of water - or both can add to the problem....</span></div><div><span style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGFm2mU_AfhbW-gPBs0KRjKDm4FfKhhWUZTV2mxsBWH_bJ2LGs47LxDlLt2kQJl_LtY0OPw2-ZtbFsg_UmtbUFfIO_CtiiPY3p7CjNZD6a-9pCoWj93p1016LFQUskosjX8p8VWYaF4FXwiXHlPEOEmuAQPVc2NGd_Vae-iTaGz3Pm1PlWNEOtZA/s960/186112346_135587428616835_2290984974388476166_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="960" data-original-width="720" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGFm2mU_AfhbW-gPBs0KRjKDm4FfKhhWUZTV2mxsBWH_bJ2LGs47LxDlLt2kQJl_LtY0OPw2-ZtbFsg_UmtbUFfIO_CtiiPY3p7CjNZD6a-9pCoWj93p1016LFQUskosjX8p8VWYaF4FXwiXHlPEOEmuAQPVc2NGd_Vae-iTaGz3Pm1PlWNEOtZA/w300-h400/186112346_135587428616835_2290984974388476166_n.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Dried out grease (photo by Deesse Bombe)</span></td></tr></tbody></table></span></div><div><span style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZo6ufrl9tN0ehgldln9RVqMkijcTNAR-VYks_6gyCol-yQofbCr5xr_cCMA15SCIq7d9fhiXmLOFFL6v3bs6TZP0rU7DMJ6BM5Mp61SW7jcYJ45Z0-8ikk6-WPzV3TMKBO626o8dUT8dj92h6nj1VU8rj-U0v5mY8z1CPjMNVu_DORqPg8wh3vw/s960/186464513_135587465283498_5678734922193733027_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="960" data-original-width="720" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZo6ufrl9tN0ehgldln9RVqMkijcTNAR-VYks_6gyCol-yQofbCr5xr_cCMA15SCIq7d9fhiXmLOFFL6v3bs6TZP0rU7DMJ6BM5Mp61SW7jcYJ45Z0-8ikk6-WPzV3TMKBO626o8dUT8dj92h6nj1VU8rj-U0v5mY8z1CPjMNVu_DORqPg8wh3vw/w300-h400/186464513_135587465283498_5678734922193733027_n.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Photo by Deesse Bombe</span></td></tr></tbody></table></span></div><div><span style="font-family: arial; text-align: justify;">That's the science over and done with. What you need to know is that something that starts off looking like this......</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjocPWR_-2UvblTEUKY9z9pds2qC0ocODfFhA5eLo9K3jYmfPZdg-Wt6o6kfhZ6pjIa9sOOhS3mlma72EbaaqozlG2W52xz2ii6h55oHReMf-EWCVV0RZ1sJq_XKgj1DxOJZIBL2gNJCDfokiAUnD0d_J8TVbQ98asS4xofSAP_WBPgMzbzF2kjXA/s960/186486135_135374425304802_6629645936312294664_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="960" data-original-width="720" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjocPWR_-2UvblTEUKY9z9pds2qC0ocODfFhA5eLo9K3jYmfPZdg-Wt6o6kfhZ6pjIa9sOOhS3mlma72EbaaqozlG2W52xz2ii6h55oHReMf-EWCVV0RZ1sJq_XKgj1DxOJZIBL2gNJCDfokiAUnD0d_J8TVbQ98asS4xofSAP_WBPgMzbzF2kjXA/w300-h400/186486135_135374425304802_6629645936312294664_n.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Polished bearing surface (photo by Deesse Bombe)</span></td></tr></tbody></table></div><div><span style="font-family: arial;">....ends up looking like this.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNAJwR4OPfja8BWeq8HVDNKOqOjnVgOpOoBytf7lBAkae0DONFrmX5XKbpn9Xv1pM9E849nxG_FWTCL_pWZ3z6XlfH6qIdTKg_6XQqqwYzs1yKAXdK6p9xzhZ9kmBZ2JpdVqk8J1gK6F89I3VQd4vJal69_nIv8QDHVl5WA3lRo26BaNRyKXrFYg/s1280/BAFD953F-A745-437F-8077-94D9E795E3EC.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="958" data-original-width="1280" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNAJwR4OPfja8BWeq8HVDNKOqOjnVgOpOoBytf7lBAkae0DONFrmX5XKbpn9Xv1pM9E849nxG_FWTCL_pWZ3z6XlfH6qIdTKg_6XQqqwYzs1yKAXdK6p9xzhZ9kmBZ2JpdVqk8J1gK6F89I3VQd4vJal69_nIv8QDHVl5WA3lRo26BaNRyKXrFYg/w400-h300/BAFD953F-A745-437F-8077-94D9E795E3EC.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Worn bearing surfaces (photo by Bleudanube)</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">To be honest, if the surfaces are that worn, new bearings and fresh grease are not going to make a lot of difference. Citrotech in Holland have a solution: they cut back the worn surface and fit modern bearings. More on that later.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Anyway, I planned to strip and examine my arms - and hopefully salvage them. I did the first part - dismantling - way back in summer 2021. The procedure for stripping and rebuilding arms (or 'front half axles' as the book calls them) is covered in Operation DX.410-3 in Citroen manual 518. That dates from 1966, but this operation is still relevant for later vehicles.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIUjvjHRKtfNll5ByNpLBev_fCz7VmNklV5RVzF3dlKPfubrtn_j4k3q-6g4OY7OsT0HJLVFB-LbNEAN1QTJjglKdBZiGed5slqdC6a6MxFlOijXnRZqZyHHBiFDMOBX3HHXT5y6euifyDLK85kViBe2zTrEAwHkHv4nVbNk7bCI8V0VEZRBCk4g/s1072/410-3.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="802" data-original-width="1072" height="299" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIUjvjHRKtfNll5ByNpLBev_fCz7VmNklV5RVzF3dlKPfubrtn_j4k3q-6g4OY7OsT0HJLVFB-LbNEAN1QTJjglKdBZiGed5slqdC6a6MxFlOijXnRZqZyHHBiFDMOBX3HHXT5y6euifyDLK85kViBe2zTrEAwHkHv4nVbNk7bCI8V0VEZRBCk4g/w400-h299/410-3.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Workshop manual</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">By chance, as I was reading up the procedure back then, someone called 'Deesse Bombe' posted on Facebook with their own efforts. And from the many photos included, they were VERY good efforts..... </span><span style="font-family: arial;">Deesse Bombe knew exactly what he was doing, how and - more importantly - why. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4vdAb6wXqtRD85ZjnoVcQdzhPzF4oRGaNjC7uxBO-Iqbf_z3YscQc0UrLPvGhss32SpLxmViC35wObu7aaQzSp2AdEESMa0YOObdj_aKCyO9y62Jao9iccYJmIutOqCCyhe5IQbq0mfVL28dVoHFr5-eUw3-uCiPeBv2mvOniNnoJWyQjBqk1Lg/s837/Deesse%20facebook.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="837" data-original-width="801" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4vdAb6wXqtRD85ZjnoVcQdzhPzF4oRGaNjC7uxBO-Iqbf_z3YscQc0UrLPvGhss32SpLxmViC35wObu7aaQzSp2AdEESMa0YOObdj_aKCyO9y62Jao9iccYJmIutOqCCyhe5IQbq0mfVL28dVoHFr5-eUw3-uCiPeBv2mvOniNnoJWyQjBqk1Lg/w383-h400/Deesse%20facebook.jpeg" width="383" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Fate lends a hand....</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Having studied the manuals and all his photo, I made contact with Deesse Bombe through Facebook. He was enormously helpful in explaining which bearings are available and where to source them. And later on in this post I'll pass those details on to you.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Guided by Deesse Bombe, and with a new spring in my step and a confident swagger, I set about dismantling my units. W</span><span style="font-family: arial;">ith the weight of the arms, the whole thing is heavy and awkward, but the unit bodies are </span><span style="font-family: arial;">soft alloy and wouldn't cope well in a vice.</span><span style="font-family: arial;"> So I rigged up a bracket to bolt them too - just like tool MR.3053-120 in manual 518 - and then clamped that bracket in my vice.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijgGS1auJ0wyzkqAs1IhGJAd4xEYKH1wqCSC93ruzwgq2b7wPVCgY54_xe6TDnMH-W8LKHQ1InCkuK3S1eSK253aUbBYbg9XhZFIwyP0OS7m1DP3d0RMOCIppXHfsLF5ob4-ZaPhA7hkRTQ4IbV-Lhh67kDQCK_8S4cMOt5djnjx9QeYsA140nFA/s4032/IMG_2990.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijgGS1auJ0wyzkqAs1IhGJAd4xEYKH1wqCSC93ruzwgq2b7wPVCgY54_xe6TDnMH-W8LKHQ1InCkuK3S1eSK253aUbBYbg9XhZFIwyP0OS7m1DP3d0RMOCIppXHfsLF5ob4-ZaPhA7hkRTQ4IbV-Lhh67kDQCK_8S4cMOt5djnjx9QeYsA140nFA/w400-h300/IMG_2990.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Suspension unit and bracket in my vice</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The nut for the bottom arm is hidden behind a protective metal cover (a 'cup'). This is part 9 in the factory photo above and is pressed into the recess. It has a threaded end to 'grab' it by. I rigged up a puller. Tightening the nut raised the bolt - which pulled the cup out. </span><span style="font-family: arial;">If the cup breaks or is jammed and needs to be ripped out, replacements are available.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjM-vgXoyr_OJE9uN1s7PQ9tlCgMmRMjv7mvwfRvReuorkboELMZcjlKxUHaEw4ONyUxloRJg8VV1B_Aa9SOceqY1_lE5nYAryGDJT88lVWZD0gITBnQdQqXNTF2sEMbkrBq6eBd0v60fqxy85Yl3k_A2jxtppQAhAriLlxpLxvtkA-htVlMda5Q/s4032/IMG_2986.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjM-vgXoyr_OJE9uN1s7PQ9tlCgMmRMjv7mvwfRvReuorkboELMZcjlKxUHaEw4ONyUxloRJg8VV1B_Aa9SOceqY1_lE5nYAryGDJT88lVWZD0gITBnQdQqXNTF2sEMbkrBq6eBd0v60fqxy85Yl3k_A2jxtppQAhAriLlxpLxvtkA-htVlMda5Q/w400-h300/IMG_2986.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Removing the 'cup' over the bottom nut</td></tr></tbody></table><span style="font-family: arial;">The nuts on the top and bottom arms are different. To prevent them loosening, the edges of the nuts are driven into a recess in each arm. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSbP6IPvbopnArIhsE9bU_sIAtmIEmWD7QSNfu2seaeVU2q0ubDcRLFFWqDJpjWCsKaUl_dXE1J396AeemYrSmsk362W1QQMiaJziBRRhU-GP7IE_0nhTOBSvCVlVC9lLztDn0kucWi9x7Tc0P_Ebz7ZZad4ntaD8SXRaTr2QS6EeDHgydPrguVA/s4032/IMG_3145.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSbP6IPvbopnArIhsE9bU_sIAtmIEmWD7QSNfu2seaeVU2q0ubDcRLFFWqDJpjWCsKaUl_dXE1J396AeemYrSmsk362W1QQMiaJziBRRhU-GP7IE_0nhTOBSvCVlVC9lLztDn0kucWi9x7Tc0P_Ebz7ZZad4ntaD8SXRaTr2QS6EeDHgydPrguVA/w300-h400/IMG_3145.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The nut is folded over to replace loosening</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Clearly, to get them off, you need to bend the folded edge of the nut back. You need to be particularly careful that you do not damage the threads on the arm when you do this, and when you remove the nuts. As a final point, you need to try and make sure you <u>salvage the nut from the top arm</u>. At the time of writing, stocks of the bottom nut can be found, but I wasn't able to find replacement top nuts. It's possible Citrotech are re-making them but I've not seen them for sale. So look after them!</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5glUwpsgztWUYT0XHr5VzFkQbIZrMqoNFhyoqImfbnEfMCqmEaveQs8lrLTJ5FGipwpbHkh2ZH82Y7fSrV6Du77VNXNLPR1rB3tQQrXcbDKOxh8hTyBv-AUh2U8Z44NKixtn164VrtwkU2hF4xT_6yvB4dPAMbfEqNL1NUs1xmGz7Y74WRupNbg/s4032/IMG_5001.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5glUwpsgztWUYT0XHr5VzFkQbIZrMqoNFhyoqImfbnEfMCqmEaveQs8lrLTJ5FGipwpbHkh2ZH82Y7fSrV6Du77VNXNLPR1rB3tQQrXcbDKOxh8hTyBv-AUh2U8Z44NKixtn164VrtwkU2hF4xT_6yvB4dPAMbfEqNL1NUs1xmGz7Y74WRupNbg/w400-h300/IMG_5001.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">New and old bottom arm nuts. Top nuts are not available</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">You will also need BIG sockets for this work: 46mm for the top arm nut and I think 38mm for the bottom one (I actually used a 1 1/2" socket that I had). With the nut's removed.......nothing happens! The arms need some 'encouragement' to leave the housing. The top arm seemed to need greater encouragement as the arm also passes through the pivot that is at the base of the suspension cylinder.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I used a stout piece of timber and a hammer. Be aware that the top arm has splines which fit onto the suspension lever - the bit with the rubber bump stops on it. When you knock the top arm out, this will release the lever part AND ia thrust washer. Carefully note the order and orientation of these.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgT_L0YWDEzybvNNam0xC6dH_j0KwYT5RakDKRo363pdq_-MNDto3E4kSDgBhR9CS4cPtfECLtRCfRoWMCIGViT5TN2YFDXuNhBFBzVoR9-EkFG1cOpE_a274vXRLMJ7BexwBHgpNl6A3WAYCf937rjTcRNM6vc_qijZUq03Rj39yEE-Q3pKiU_kA/s4032/IMG_3146.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgT_L0YWDEzybvNNam0xC6dH_j0KwYT5RakDKRo363pdq_-MNDto3E4kSDgBhR9CS4cPtfECLtRCfRoWMCIGViT5TN2YFDXuNhBFBzVoR9-EkFG1cOpE_a274vXRLMJ7BexwBHgpNl6A3WAYCf937rjTcRNM6vc_qijZUq03Rj39yEE-Q3pKiU_kA/w400-h300/IMG_3146.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Lever, thrust washer and splined top arm</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">With the arms out of the way, you then need to pull out the rubber seals on the shaft ends to get at the bearings. If you are careful these could be re-used, but you can also buy replacements. </span><span style="font-family: arial;">Note in the photo that the lip of the seals at the arm ends sticks out a little.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg735NClA9H3_uOgYG77rL3xLiOkaW-apqghM3WH6pR18O0lKJI8W8CUIzHGEt5xWoZWxp-VXhmtKctzVybZNTTzmUJuuBN4bBVFtWGuKfHDfphrbPvV3IaspDmCZzbXUCc_aYN3PeiHRasPb2QeJLyHGc145RWMx7yPJYuq2TfJYofaZldSJJhyQ/s4032/IMG_3131.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg735NClA9H3_uOgYG77rL3xLiOkaW-apqghM3WH6pR18O0lKJI8W8CUIzHGEt5xWoZWxp-VXhmtKctzVybZNTTzmUJuuBN4bBVFtWGuKfHDfphrbPvV3IaspDmCZzbXUCc_aYN3PeiHRasPb2QeJLyHGc145RWMx7yPJYuq2TfJYofaZldSJJhyQ/w400-h300/IMG_3131.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Rubber seal over the end of the bearing</span></td></tr></tbody></table><span style="font-family: arial;">With the seals removed, the roller cage part of the bearing simply lifts out in a gooey mess of protective grease. What is left behind is the bearing cone lining the hole in the suspension unit. These are pressed into the unit so won't simply fall out. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiam1n9utObWK3aEIEcZBuuHje4BWAODk1JfvowalXMcHiM7thE-HFr46oXXB_QoqKFmYHnOiDBDCFK3Kjbz_YiVgP40vyp7a4JNN8Jn14hl1A7dyCJNcmbNwkwspaSFYfRZQS7eyLH1UsR7ZDmKOzH60YrybFrc_p0iQmcAj4LTzYVYPTHiXFURQ/s4032/IMG_3137.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiam1n9utObWK3aEIEcZBuuHje4BWAODk1JfvowalXMcHiM7thE-HFr46oXXB_QoqKFmYHnOiDBDCFK3Kjbz_YiVgP40vyp7a4JNN8Jn14hl1A7dyCJNcmbNwkwspaSFYfRZQS7eyLH1UsR7ZDmKOzH60YrybFrc_p0iQmcAj4LTzYVYPTHiXFURQ/w400-h300/IMG_3137.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Bearing cone pressed into the unit. See the light patterns from wear</span></td></tr></tbody></table><span style="font-family: arial;">If you clear out the grease and peer inside with a torch, you will see that the backs of the seats for the cones have a little notch. Just enough to get some purchase on the cone with a long drift and hammer.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoNW_EPNF3tJ0kbictVUwRpL3axIcZZ-Q0DY4jEdCFF6Lf_oEiXhKez_zhLlfCNfg4lVnKqDLhLR6VUo_IdCO6ad_K8CLFby-wgnbJl4J4vVFaTG5zKkVu_AntG9hxmKcgRPKkOM1N2JSkk3SM_xu8DOt59evoNtoZ89LM-BiWq0rl1ndzmL-Mww/s4032/IMG_4983.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoNW_EPNF3tJ0kbictVUwRpL3axIcZZ-Q0DY4jEdCFF6Lf_oEiXhKez_zhLlfCNfg4lVnKqDLhLR6VUo_IdCO6ad_K8CLFby-wgnbJl4J4vVFaTG5zKkVu_AntG9hxmKcgRPKkOM1N2JSkk3SM_xu8DOt59evoNtoZ89LM-BiWq0rl1ndzmL-Mww/w400-h300/IMG_4983.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">You can just see the notch behind the cone</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The technique is to first apply a little heat to the alloy unit around where the cone is sitting. </span><span style="font-family: arial;">I used a hot air paint stripping gun as a heat source. </span><span style="font-family: arial;">This causes a little expansion and means the cone is more easily removed with a drift. I worked around the diameter of each cone, tapping as I went, and took my time so that the cone came out straight and did not snag. I added a bit more heat from time to time. When the cones fall out, you'll be tempted to catch them - careful they'll be hot!</span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFUEPf7rJdhumYxwB1NM8c7M1epl3ByYEumz73YpIDEBvLNYseK9gU0xcCa2VRKtT4OeLN67LrOCqTrJn0cXKjKXZy4Nho2txKHqxEqcxg2dg0UacB6bMY0pxAEeuUmwLvJ_k6ar1pc3evIsgTsoAtubdoZABI9B_A96oygc5oQKzeZS0ciUjdEQ/s4032/IMG_5408.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFUEPf7rJdhumYxwB1NM8c7M1epl3ByYEumz73YpIDEBvLNYseK9gU0xcCa2VRKtT4OeLN67LrOCqTrJn0cXKjKXZy4Nho2txKHqxEqcxg2dg0UacB6bMY0pxAEeuUmwLvJ_k6ar1pc3evIsgTsoAtubdoZABI9B_A96oygc5oQKzeZS0ciUjdEQ/w400-h300/IMG_5408.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Suspension taper roller bearing and cone</span></td></tr></tbody></table><div style="text-align: justify;"><span style="font-family: arial;">I examined the cone face and the bearing contact face on the arm. I could feel no grooves when I ran my fingertips around, but they clearly caught the light differently - which was the telltale sign of where they had been in contact and under pressure. My grease was still wet and in place and there were no signs of rusting or significant failure. I was relieved to conclude that these were salvagable.</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLi1aizA0quEcSviCPoEaBIrZ7SjBiJ1hLu2wbOVQNYTRsjuaKzD0StmF74gBM6GWeNh9uRYPJjEMtbVdgFkmJcaX6C4HfWrm3INpk27fjUuU6s6D58MN8d_-5EQEmDNM5nJWINuewdIqPuLoODtPrZ1DtzTNYlEoT3gE9WgZGiKGvr2I8RwOiOg/s4032/IMG_2991.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLi1aizA0quEcSviCPoEaBIrZ7SjBiJ1hLu2wbOVQNYTRsjuaKzD0StmF74gBM6GWeNh9uRYPJjEMtbVdgFkmJcaX6C4HfWrm3INpk27fjUuU6s6D58MN8d_-5EQEmDNM5nJWINuewdIqPuLoODtPrZ1DtzTNYlEoT3gE9WgZGiKGvr2I8RwOiOg/w400-h300/IMG_2991.JPG" width="400" /></a></div><span style="font-family: arial;">All the parts were put aside while I moved on to sourcing bearings, seals and nuts - as per Deesse Bombe's helpful advice.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggeCFHIJjNM17z_ajEPfgs0QHVPwx03ZkssOadpz4cf4g1V0x7aHOL0QJxl2KOSHsPnROm18ZUYDcckOsYs7nuDlvY7ZTTc7uQlYhIeTvcraXZW4BL03ojSem8-oOXzyQvsFNm7RCcsYvWH9qSy5W5SPcyPaMfHO4aZnkmQMAyTW_uUoXt-Y9K-A/s4032/IMG_3140.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggeCFHIJjNM17z_ajEPfgs0QHVPwx03ZkssOadpz4cf4g1V0x7aHOL0QJxl2KOSHsPnROm18ZUYDcckOsYs7nuDlvY7ZTTc7uQlYhIeTvcraXZW4BL03ojSem8-oOXzyQvsFNm7RCcsYvWH9qSy5W5SPcyPaMfHO4aZnkmQMAyTW_uUoXt-Y9K-A/w400-h300/IMG_3140.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">One side done.....</span></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9oyM9ovRSQl90Es_884xLlTxTUylMqV_p05qiJdNp1eWZlMcQA-VzDrPCLSOfj7XZHT1hoGLdionIbLobEZX3xfQ5zMOSsp806Li3MO4XwniDAW6W72aH_DiM7BMQ442nbmHd_jBSRow--00-LMNLyJepYKvz2dvPZckKmYXtv4C7LuCgZLYPFw/s4032/IMG_3141.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9oyM9ovRSQl90Es_884xLlTxTUylMqV_p05qiJdNp1eWZlMcQA-VzDrPCLSOfj7XZHT1hoGLdionIbLobEZX3xfQ5zMOSsp806Li3MO4XwniDAW6W72aH_DiM7BMQ442nbmHd_jBSRow--00-LMNLyJepYKvz2dvPZckKmYXtv4C7LuCgZLYPFw/w400-h300/IMG_3141.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">......one side still to go</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Sourcing Replacement Bearings</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">Here is a diagram showing the bearings inside an arm. In this case a lower arm. The bearing cones (that are pressed into the unit) are shown in red. The bearings are nestling inside these. Note how the bearing at the arm end contacts a tapered face on the arm, whereas the bearing at the nut arm has a lining which contacts a straight (two parallel sides) section of the arm. </span><span style="font-family: arial;">Part 10 is a protective rubber seal at the arm end. Part 3 is a protective metal cup over the nut end. Part 12 is a metal spacer (a shim) that sits behind the front cone. More on that later......</span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigG6ND9boDljYgcStqDnunzZl9i1QvbuUb0UbezlPwbWswt5Mh1VrDfW66fWA0wF_ZcJeXe-1k0awb5h_45Rl9VYC6PbZ3TcF7jbFe0yf8YYMQpwMkMjIfD0HnPHGPJoD4lKfKHj__T4vRPqJxMuYKZVBzqGiE3sGez8uVFx7xym_3mlYJ0eHACQ/s1149/Bushes%202%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="701" data-original-width="1149" height="244" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigG6ND9boDljYgcStqDnunzZl9i1QvbuUb0UbezlPwbWswt5Mh1VrDfW66fWA0wF_ZcJeXe-1k0awb5h_45Rl9VYC6PbZ3TcF7jbFe0yf8YYMQpwMkMjIfD0HnPHGPJoD4lKfKHj__T4vRPqJxMuYKZVBzqGiE3sGez8uVFx7xym_3mlYJ0eHACQ/w400-h244/Bushes%202%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Cutaway of a lower suspension arm</span></td></tr></tbody></table><div style="text-align: justify;"><span style="font-family: arial;">The top arm arrangement is pretty similar. In fact the front (arm end) bearing and rubber seal is the same as on the bottom arm. The rear (nut end) bearing is different to the nut end bearing on the lower arm and has a rubber protective seal rather than a metal cup. The main difference on the top arm, is that it also carries the lever for the suspension cylinder.</span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLGu_paQFo6oTGOGr-NlHpj5nEd03jTmAnvoxpp8MdB3zP79HcVqpFPFi3oMgaTTUHAighIJeZ03Cwg8S2tAubaro6sd6WH8NYY0uqy4HwPQelo0Je_oZXSx1pXNL3ibTlFSNr20zEcbgP2x78qIfixZwjnGEt9DnEqnWukb5bpu1KuAsmtvxO_w/s859/562%20parts.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="739" data-original-width="859" height="344" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLGu_paQFo6oTGOGr-NlHpj5nEd03jTmAnvoxpp8MdB3zP79HcVqpFPFi3oMgaTTUHAighIJeZ03Cwg8S2tAubaro6sd6WH8NYY0uqy4HwPQelo0Je_oZXSx1pXNL3ibTlFSNr20zEcbgP2x78qIfixZwjnGEt9DnEqnWukb5bpu1KuAsmtvxO_w/w400-h344/562%20parts.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The lever fits on splines on the nut end of the upper arm</span></td></tr></tbody></table><div style="text-align: justify;"><span style="font-family: arial;">The bearing sizes are given in the parts manual though the part numbers themselves changed over the years. Deesse Bombe kindly explained what bearings were needed for where, and what replacements were available. And weren't. I've tabulated them here. Click on the image to enlarge it. </span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhz4PkAcdES53Yy_5t2vNuHQGsLcXRjh6lvQbz38ZYIfzhUhDLjWhoi6YQFXW3cZjp20EHwhF3d99IatWIOSTQtxLWnvXp0Bwp9Yxt9trc2F7fJZVqBhojvGcmwQyvVf4bUkec-HbZqlYhgPlam5sWVyVGTiOei-mKtWyoUvNJLoS11ATkrNIcQvQ/s3217/suspension%20bearing%20sizes2%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1849" data-original-width="3217" height="368" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhz4PkAcdES53Yy_5t2vNuHQGsLcXRjh6lvQbz38ZYIfzhUhDLjWhoi6YQFXW3cZjp20EHwhF3d99IatWIOSTQtxLWnvXp0Bwp9Yxt9trc2F7fJZVqBhojvGcmwQyvVf4bUkec-HbZqlYhgPlam5sWVyVGTiOei-mKtWyoUvNJLoS11ATkrNIcQvQ/w640-h368/suspension%20bearing%20sizes2%20copy.jpg" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Front arm bearings</span></td></tr></tbody></table><div style="text-align: justify;"><span style="font-family: arial;">The 'arm side' bearings and cones (ZC 9620 051 and ZC 9620 052) are not available as modern equivalents. At the moment there seems to be a fair number of 'new old stock' Citroen originals available - though prices vary widely!</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiQtD-x3lhcf8y8I2-hMUXlrp3hXlSncsT_Km5jcOsCntlIE54ksbPD3reiNclmcycbfwD5wanyNKUJ4ednBi7TTXFtmYNyRXAcbyx9Q9HCVxvI9RmxQIC2y9rVSKICNh9mjPrnweIFt13mmXx37wFlGzSsKlAP3KBsCvXYgPlRXZploaVFf3uKQ/s1057/bearings3.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="798" data-original-width="1057" height="303" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiQtD-x3lhcf8y8I2-hMUXlrp3hXlSncsT_Km5jcOsCntlIE54ksbPD3reiNclmcycbfwD5wanyNKUJ4ednBi7TTXFtmYNyRXAcbyx9Q9HCVxvI9RmxQIC2y9rVSKICNh9mjPrnweIFt13mmXx37wFlGzSsKlAP3KBsCvXYgPlRXZploaVFf3uKQ/w400-h303/bearings3.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Original - but expensive</span></td></tr></tbody></table></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLZJrNJs8AxyH9sNByOXxJnWcU816Btthcccs-YqTHM2JKglQXKhlMaL3gZ7WYJ1KI6kVPOiV8XtsTVs8BIfdWxXjmIriSwf3bj3VHvwvlskp6bPelDMk9bhJzKhfdQtzACyeql5dgq8BVh7mm4ySqg1Qn8cSUFUMSWqHHjgpaLv3mWVffR28q6A/s1104/bearings.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="489" data-original-width="1104" height="178" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLZJrNJs8AxyH9sNByOXxJnWcU816Btthcccs-YqTHM2JKglQXKhlMaL3gZ7WYJ1KI6kVPOiV8XtsTVs8BIfdWxXjmIriSwf3bj3VHvwvlskp6bPelDMk9bhJzKhfdQtzACyeql5dgq8BVh7mm4ySqg1Qn8cSUFUMSWqHHjgpaLv3mWVffR28q6A/w400-h178/bearings.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">But bargains can be found!</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">MUCH harder to find are the 'nut side' upper arm bearings - ZC 9620 115U. If you can find these, they may cost you more than £150 each. For those reasons, it's perhaps best to just re-pack and re-use the ones in your arms if you can.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">The bearing and cone of modern bearing 32206 are suitable replacements for the nut end bearing of the lower arm. The bearing thickness (not it's diameters) is very slightly less than the Citroen original (0.25mm) but - being the nut end bearing - this makes no significant difference to the geometry of the arms.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">If you are buying new bearings I was offered the following advice:</span></div><blockquote style="border: none; margin: 0px 0px 0px 40px; padding: 0px; text-align: left;"><div style="text-align: justify;"><span style="font-family: arial;">- Buy good quality SKF J2/Q bearings</span></div><div style="text-align: justify;"><span style="font-family: arial;">- Avoid non-European manufacture (though SKF have quality control - right?)</span></div><div style="text-align: justify;"><span style="font-family: arial;">- Avoid cheap Ebay bargains - there are counterfeit SKF bearings out there....</span></div></blockquote><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhebbL6PWJL9BKlw-4xSmsy-Q2r4nIJnTTcUFY6DNv2xID-YMtoDgwueasNTmj-NQEyp9CyJBEO5-ct40_lwv8cUrzBV5HmdeHEbhedbZVYtO9WL8Keqt3eXjUbhyCRGndqrRS-wUk2LV6w0bbTXP1kkgqWnkKaYFh2SAbtgJsm84e6q5_W_xe1LQ/s4032/IMG_3162.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhebbL6PWJL9BKlw-4xSmsy-Q2r4nIJnTTcUFY6DNv2xID-YMtoDgwueasNTmj-NQEyp9CyJBEO5-ct40_lwv8cUrzBV5HmdeHEbhedbZVYtO9WL8Keqt3eXjUbhyCRGndqrRS-wUk2LV6w0bbTXP1kkgqWnkKaYFh2SAbtgJsm84e6q5_W_xe1LQ/w400-h300/IMG_3162.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">32206 bearings</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Painting The Parts</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">I next picked up this job in June 2022. I de-greased and then cleaned all the iron parts on a wire wheel and with an electric drill. The main alloy bodies are an awkward shape with many nooks and crannies and I had them vapour blasted. </span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEif_3k8I8kYYEXckJXSfeAVFY2s9FC6wZ7MXdLpTytfTtRX2_-PynuEQ2Q2mwazHQVGMBSY3M_wFeolH6xzw5-NLWMZXZXOzevAtwiTo9bQXSRdl3pS16uqKKjnzem9yv2qM_JTvqYcFyaIIyC6UmbNiA9nQti5dEunEfJVEvRowpNh0LoPSLc40g/s4032/IMG_3247.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEif_3k8I8kYYEXckJXSfeAVFY2s9FC6wZ7MXdLpTytfTtRX2_-PynuEQ2Q2mwazHQVGMBSY3M_wFeolH6xzw5-NLWMZXZXOzevAtwiTo9bQXSRdl3pS16uqKKjnzem9yv2qM_JTvqYcFyaIIyC6UmbNiA9nQti5dEunEfJVEvRowpNh0LoPSLc40g/w400-h300/IMG_3247.JPG" width="400" /></a></div><span style="font-family: arial;"><div style="text-align: justify;">Again, following a tip from Deesse Bombe - and although I couldn't feel any roughness with my fingertip - I polished the bearing contact surfaces of my arms. Judging by the way the light reflected off them, It did make a difference with the surface being more consistent.</div><div style="text-align: justify;"><div style="font-family: -webkit-standard;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhG9S5tuczcCDHB7AiSCh9gdl2No5Yq7G04B9c0ch4HFSCRe9uYrZMhBoPwCY-kH0scvGe0SbDa0o7dZrDBcT5EFsQXFR8sBU2Gme0EHl-K4FWsIR9_myIsyc6ILidOWtRF5ONHJbnrqOfuARTGgv-SAMQ2DNhTpoD_0A7E4I4-vPuZulo6vQXHZg/s4032/IMG_4939.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhG9S5tuczcCDHB7AiSCh9gdl2No5Yq7G04B9c0ch4HFSCRe9uYrZMhBoPwCY-kH0scvGe0SbDa0o7dZrDBcT5EFsQXFR8sBU2Gme0EHl-K4FWsIR9_myIsyc6ILidOWtRF5ONHJbnrqOfuARTGgv-SAMQ2DNhTpoD_0A7E4I4-vPuZulo6vQXHZg/w400-h300/IMG_4939.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Polishing the arms - a 'before' and an 'after'</span></td></tr></tbody></table></div></div><div style="text-align: justify;">I was painting the steering relays and anti-roll bar at the same time. Everything was degreased with panel wipe......</div></span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyzgOTTHDx4SIyUdFVkYeOhmy0z6Kjjbgu0GY1-OKAAU8JaxrNbOOf49jgLuQUYKM9gcs6TUIBNbXaG9TjBGsTkVkEdgJbQ9yzXmtT44oEb1ASjHQOHA13qiOweAkC05VPXB4IoSTrpfZDZEeAyQOYcDNIxgmACl9h3NwPp7hUHoPmX7UhNmkzAw/s4032/IMG_4941.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyzgOTTHDx4SIyUdFVkYeOhmy0z6Kjjbgu0GY1-OKAAU8JaxrNbOOf49jgLuQUYKM9gcs6TUIBNbXaG9TjBGsTkVkEdgJbQ9yzXmtT44oEb1ASjHQOHA13qiOweAkC05VPXB4IoSTrpfZDZEeAyQOYcDNIxgmACl9h3NwPp7hUHoPmX7UhNmkzAw/w400-h300/IMG_4941.JPG" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">........and then got a coat of epoxy primer.</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx4PpxHTIlkNzUZMK3YxTlH6DmzXhfkw9R8p5wvtvAr383aUBNUFQ9Kue9gzSlqu2pturZ2vIMTj32ImaeeRN5EhByTE_RGqSg-KZDereFpk1snMe8rvRIcnJ3jYme3S505dxgXXWHnojNLmano1FSni-DXGzF0S1ZJXScIPOgEEq0InitfRXF2A/s4032/IMG_4959%201.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjx4PpxHTIlkNzUZMK3YxTlH6DmzXhfkw9R8p5wvtvAr383aUBNUFQ9Kue9gzSlqu2pturZ2vIMTj32ImaeeRN5EhByTE_RGqSg-KZDereFpk1snMe8rvRIcnJ3jYme3S505dxgXXWHnojNLmano1FSni-DXGzF0S1ZJXScIPOgEEq0InitfRXF2A/w400-h300/IMG_4959%201.JPG" width="400" /></a></div><span style="font-family: arial;">I finished off with two coats of gloss. And everything was literally hung out to dry....</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpYZzNGrxK_nQjcsqP-BY_pb1Mn0Ow2L19EJ4N_2aqJfSugBkSu4KJNAQnuMOH0VTNAv9vWLuQ9EeIYzh11NVb0PNRpBdNBbYbZXxqfYTH8BvRh9zEIgjGsZTz_OO-kMd6zwVYnGCUs2Ql3nPSJt4FY9O1OBLuhx-V8fjX8IQ2S0zlX2YFG8zUdg/s4032/IMG_4964.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpYZzNGrxK_nQjcsqP-BY_pb1Mn0Ow2L19EJ4N_2aqJfSugBkSu4KJNAQnuMOH0VTNAv9vWLuQ9EeIYzh11NVb0PNRpBdNBbYbZXxqfYTH8BvRh9zEIgjGsZTz_OO-kMd6zwVYnGCUs2Ql3nPSJt4FY9O1OBLuhx-V8fjX8IQ2S0zlX2YFG8zUdg/w400-h300/IMG_4964.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">It's what gardens were made for</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">By now I'd sourced all the bearings, seals and nuts I planned to use. As per my tale above, the bearings were a mix of genuine Citroen bearings and new SKF bearings.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9LJuMuf7UgNg_cUPtl8X_Z0n1W2PdDPbupory4KBBnwdpC9EYrHkVzegY1xxEEG7gSsMnnZ-vnrdWXWUDXhmI7NEtlvstTHOS-yQhdIMftt3oC1VxUdRtirNyBOujM2155K8wtVZzByXuO77ecul6aaBnlQaWMDX4G7OokK4FKi_jlAnEm1LNcw/s4032/IMG_4969.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9LJuMuf7UgNg_cUPtl8X_Z0n1W2PdDPbupory4KBBnwdpC9EYrHkVzegY1xxEEG7gSsMnnZ-vnrdWXWUDXhmI7NEtlvstTHOS-yQhdIMftt3oC1VxUdRtirNyBOujM2155K8wtVZzByXuO77ecul6aaBnlQaWMDX4G7OokK4FKi_jlAnEm1LNcw/w400-h300/IMG_4969.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">All ready</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The new bearings have a protective light oil coating but no more than that and, before the bearings can be used, they need to be packed with grease. I had thought of heating a large pot of grease up beyond melting point then dropping the bearings in until it cooled and 'set'. But that is very wasteful of grease. Especially as it's advisable to be using a good quality grease. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Bearing Grease</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">SKF 'VKG 1/1' was recommended to me. It's an extreme pressure grease suitable for high load, low speed applications. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigOLW7lAo7abv5uYNdCKuh6i7LCj78wYOyXj0Zbd7xzrS4utsI4TRnN-WCtM4m3OT7_A2-Tgh8d1o_JJVAoBb0bO8-9c8iavTV8MrVaDGgw5s15BmyLPcR3dpCu1G3CFDHNFxh6A5f-LAbqBGF54Pl-e9H-9U2Gw-LOsCPChQc4ofKWQ36lOGHuQ/s626/VKG1.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="362" data-original-width="626" height="231" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigOLW7lAo7abv5uYNdCKuh6i7LCj78wYOyXj0Zbd7xzrS4utsI4TRnN-WCtM4m3OT7_A2-Tgh8d1o_JJVAoBb0bO8-9c8iavTV8MrVaDGgw5s15BmyLPcR3dpCu1G3CFDHNFxh6A5f-LAbqBGF54Pl-e9H-9U2Gw-LOsCPChQc4ofKWQ36lOGHuQ/w400-h231/VKG1.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">SKF 'VKG1' Grease</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">However I'm not convinced SKF still market this but it is still available here and there. Possibly old stock? I eyed up 'LGEP 2' - which is also an extreme pressure grease but it seems aimed at </span><span style="font-family: arial;">VERY big machinery and I was worried it would be very thick and heavy - which is certainly not like the grease I removed from the bearings. </span><span style="font-family: arial;">In the end, and on advice from my bearing supplier, I used SKF 'LGMT 2' grease, which is said to be suitable for automotive applications. I think that's what Deesse Bombe used too. If I was doing this again (and who says I won't be!) I might go for LGEP2 as 'extreme pressure' should be a major consideration......Remember 'brinelling' at the start of this post?</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Packing bearings involves </span><span style="font-family: arial;">having a large blob of grease in your palm and then, with the other hand, pressing the bearing down and across the grease blob. The idea is to force the grease up between the rollers of the bearing.Rotate the bearing so that you pack all the way around. </span><span style="font-family: arial;"> It's quite messy. The grease in your hand melts (especially in a heatwave!) and I couldn't take any photos of the technique, but there is</span><span style="font-family: arial;"> a short and helpful video on Youtube </span><a href="https://www.youtube.com/watch?v=BhL1uAp_WCw&t=100s" style="font-family: arial;" target="_blank">HERE</a><span style="font-family: arial;">. </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Refitting The Bearing Cones</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">The trick was going to be replacing the cones in the arm unit. From his photos on Facebook, Deesse Bombe used a puller set to refit the cones. It </span><span style="font-family: arial;">can also help with the removal of one or two, but not all. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcTiSSPI07xcfdvhbSaWb10rydrgjz6MYJDH7DBARX4wn3jeGcPceHXTd4OghQsUTgzOyFyrtYHkc_JdIKzHEvnQW3j7uO-e8Ylx3wkkG5B7yuKJQmO8Y3dvJMYiTBrWo8oNhGQYA9B-LkCeM7grRJ-4x6QJcKNSHNDX39Ba6sZQ-yFF8QuU-mPQ/s960/186939936_135707075271537_4896852169577094809_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="540" data-original-width="960" height="225" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcTiSSPI07xcfdvhbSaWb10rydrgjz6MYJDH7DBARX4wn3jeGcPceHXTd4OghQsUTgzOyFyrtYHkc_JdIKzHEvnQW3j7uO-e8Ylx3wkkG5B7yuKJQmO8Y3dvJMYiTBrWo8oNhGQYA9B-LkCeM7grRJ-4x6QJcKNSHNDX39Ba6sZQ-yFF8QuU-mPQ/w400-h225/186939936_135707075271537_4896852169577094809_n.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Bearing puller set (photo by Deesse Bombe)</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I'll confess now and say I followed his lead so closely, I even got EXACTLY the same set....it was a June 2021 birthday gift, so even though I didn't use half of the pieces in the kit, I didn't feel so guilty - and it certainly made the job a lot simpler.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">The set offers a range of discs of different diameter which can be used to pull the cones gently into place. Obviously you want to make sure your disc diameter is wide enough to contact the edges of the cone - but not so wide that the disc gets jammed in the arm unit..... The shape of the alloy unit means that you will need to vary the puller set up according to which cone you are replacing.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsKQX1ExBf2A0p8nsGqclNnMQBJtuXB1dUyO5tSlltPXGTUhJ7-n7hhMZRn__-AnHvE0tpgtCKYu4Hf3cUvPkjmnP7BEwLii52Wujw4tbhSsPZ6y_1soP6H14IJBcgICobaUf_oSFj14cBxKQukHHgrRLN-qp6YPr3Idp28lzERqTJtLrDzgMB-Q/s4032/IMG_4978.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsKQX1ExBf2A0p8nsGqclNnMQBJtuXB1dUyO5tSlltPXGTUhJ7-n7hhMZRn__-AnHvE0tpgtCKYu4Hf3cUvPkjmnP7BEwLii52Wujw4tbhSsPZ6y_1soP6H14IJBcgICobaUf_oSFj14cBxKQukHHgrRLN-qp6YPr3Idp28lzERqTJtLrDzgMB-Q/w400-h300/IMG_4978.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Fitting a top arm arm-side cone</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">The cone of the 'nut side' bearing of the top arm is recessed inside the alloy unit. Fitting the cone means choosing a plate that fits inside the unit. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRciRXzYQndZgDddD2VZ9fWW1EyX0N4g3hbRiqViGnaU_JGiqsOCt3da4qKrcfWGXjNrCB67OpBjwQz1K453J2cAkyXyINFjf90TR5BDwCX_A2GbsGl9HTUsWMMPHkrbxkLRrd5ncD1-XipBjotG7TXbXyPdG3xLvMaHxBbg6nHanGSBFJgroQHw/s4032/IMG_5041.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRciRXzYQndZgDddD2VZ9fWW1EyX0N4g3hbRiqViGnaU_JGiqsOCt3da4qKrcfWGXjNrCB67OpBjwQz1K453J2cAkyXyINFjf90TR5BDwCX_A2GbsGl9HTUsWMMPHkrbxkLRrd5ncD1-XipBjotG7TXbXyPdG3xLvMaHxBbg6nHanGSBFJgroQHw/w400-h300/IMG_5041.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Choosing the right tool for the job</span></td></tr></tbody></table></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYwtbiJoq99Ck0jjStee57flVHeznFyrLRojeWcp9BVhMVarNW6vBSnFf6vi5Jp-eWTtJAmz-BfvJFNJz44kPrFwx2R1XkdLDnZRbQyIFdFG3Fw930b2BuKl2FC-3OXPr9O-gXsMqkp1OQROuXXr3DrquUsJ3ZN6J575yo1wQeWqJnRa8nG7H3SQ/s4032/IMG_5042.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYwtbiJoq99Ck0jjStee57flVHeznFyrLRojeWcp9BVhMVarNW6vBSnFf6vi5Jp-eWTtJAmz-BfvJFNJz44kPrFwx2R1XkdLDnZRbQyIFdFG3Fw930b2BuKl2FC-3OXPr9O-gXsMqkp1OQROuXXr3DrquUsJ3ZN6J575yo1wQeWqJnRa8nG7H3SQ/w400-h300/IMG_5042.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Just the right size to go inside the alloy unit.</span></td></tr></tbody></table></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMXleSv4AO7cPOHp-nmprUE4uJ4KcYOK-7kQLFoc0nyVWEDEXveB30XBXQOi9SMmAILmI8_F70f-EQr_cAOfWJZcrg0I1GlHA9lbOCkQUX3q2pVPxKEetfz7oIbJKfA0lodvc5B1BA8V2fqAUg7tNalHpi3TrMoViM5Zj7oqD7nQgtfurxmIeCHw/s4032/IMG_4977.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMXleSv4AO7cPOHp-nmprUE4uJ4KcYOK-7kQLFoc0nyVWEDEXveB30XBXQOi9SMmAILmI8_F70f-EQr_cAOfWJZcrg0I1GlHA9lbOCkQUX3q2pVPxKEetfz7oIbJKfA0lodvc5B1BA8V2fqAUg7tNalHpi3TrMoViM5Zj7oqD7nQgtfurxmIeCHw/w400-h300/IMG_4977.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Winding in a top arm nut-side cone</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">As with removal of the cones, applying some heat around the circumference of the alloy unit helps to expand things and making refitting easier.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><div><span style="font-family: arial;"><b>Refitting The Top Arm</b></span></div><div><span style="font-family: arial;">The idea is that you refit and tighten the TOP arm first, then move on to the bottom arm - checking the castor and adjusting the shims as need be. More on that later.... I loaded the bearing and seal with grease before fitting.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkf6Fevw3dbjvxGfsk6eanFqloJLkjSUaLwUzIzErrmeSBiyDNAy-7TlK9a3Uw6iCn8nYLMQTdYfInup7kZZ_MsjQNf8XpQmUWhChBTadyofaBym4_4i-jfKhSjUBIv1cknyz5WVlLCnem7KqHcIJbasjeYiMqsjj2O1beoXIkc4Qu4Qpdij04pw/s4032/IMG_5057.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkf6Fevw3dbjvxGfsk6eanFqloJLkjSUaLwUzIzErrmeSBiyDNAy-7TlK9a3Uw6iCn8nYLMQTdYfInup7kZZ_MsjQNf8XpQmUWhChBTadyofaBym4_4i-jfKhSjUBIv1cknyz5WVlLCnem7KqHcIJbasjeYiMqsjj2O1beoXIkc4Qu4Qpdij04pw/w400-h300/IMG_5057.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Arm side bearing and seal ready to fit</span></td></tr></tbody></table></div><div><span style="font-family: arial;">There are special tools for fitting the seals to the correct depth(!).</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdBU8pQ1D9GYBXv98WGI3J2PnMgicZPDTpDPixFLx1ePt1_6arWpRj0F_uCOMBxlN796WSJwEjrj-jtnvuCvRJOKYD3UWAtauF9q7bnXd9P9GIeNV30xXayWktHSowD3Ke0Bt9N_MFDvuUtrLWGydVD-FOirqWDer1TFhi2pSmH8h7BCpmBRPaoA/s964/shim%20tools.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="760" data-original-width="964" height="315" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdBU8pQ1D9GYBXv98WGI3J2PnMgicZPDTpDPixFLx1ePt1_6arWpRj0F_uCOMBxlN796WSJwEjrj-jtnvuCvRJOKYD3UWAtauF9q7bnXd9P9GIeNV30xXayWktHSowD3Ke0Bt9N_MFDvuUtrLWGydVD-FOirqWDer1TFhi2pSmH8h7BCpmBRPaoA/w400-h315/shim%20tools.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Tools for setting the depth of the seals</span></td></tr></tbody></table></div><div><span style="font-family: arial;">I don't ever expect to see those tools in my lifetime - let alone own a pair. Measurements/ gaps are given in manual 518, but I think the key thing to note when rebuilding the top arm is that the</span><span style="font-family: arial;"> </span><u style="font-family: arial;">body</u><span style="font-family: arial;"> </span><span style="font-family: arial;">of the seal on the arm side is recessed into the alloy unit slightly (see 'r' above), whereas for the same seal on the lower arm, the</span><span style="font-family: arial;"> </span><u style="font-family: arial;">body</u><span style="font-family: arial;"> </span><span style="font-family: arial;">is fitted flush to the unit. What you <u>don't</u> want to do is squash the seal in and up against the roller bearing. There should be a small gap between the two to allow grease to gather there and feed the end of the bearing if need be</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ97NqqESnLS8LkyvbtYxuEhqvKjsjdGEqidC_G7-JVFWKduOnTiQGKHIBk-ji_2syq_1vEZYhStxtLYQkNWjZqie4wSzfVd7ssvdBpSEGZP9EgddDXHp0cP7ma2KI6jxtZiZAAL-th99tLSEgztUs-YBQWOiVmKBxhoE35p1D0nbmIJTB5FiIoA/s4032/IMG_5054.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ97NqqESnLS8LkyvbtYxuEhqvKjsjdGEqidC_G7-JVFWKduOnTiQGKHIBk-ji_2syq_1vEZYhStxtLYQkNWjZqie4wSzfVd7ssvdBpSEGZP9EgddDXHp0cP7ma2KI6jxtZiZAAL-th99tLSEgztUs-YBQWOiVmKBxhoE35p1D0nbmIJTB5FiIoA/w400-h300/IMG_5054.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Leave a gap between the seal and the bearing</span></td></tr></tbody></table></div><div><span style="font-family: arial;">Extra grease (the manual says about 50 grammes) </span><span style="font-family: arial;">was added into the recess </span><span style="font-family: arial;">and all around the bearings and seals. </span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFDMmgnggYAMmdpXiHdjrTzIj63NuObca4RgLxdRAClmw8vM3VgSnoh4tSKcP6BBK9C8XiVIXV9vfsfvCsH9gctI8MM6tG6zsKZ_OYf8pQtbUQsrq457_bzWt3AdOIwHHWliaJIWSERTg9sY0MzU6zrKS44_eN00PPqHBPd88FK57RjLzVHOjRIQ/s4032/IMG_5058.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFDMmgnggYAMmdpXiHdjrTzIj63NuObca4RgLxdRAClmw8vM3VgSnoh4tSKcP6BBK9C8XiVIXV9vfsfvCsH9gctI8MM6tG6zsKZ_OYf8pQtbUQsrq457_bzWt3AdOIwHHWliaJIWSERTg9sY0MzU6zrKS44_eN00PPqHBPd88FK57RjLzVHOjRIQ/w400-h300/IMG_5058.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">I added extra grease inside the arm unit</span></td></tr></tbody></table><span style="font-family: arial;">Refitting the top arm is a little tricky because of the need to line up the big suspension lever part to the splines on the arm. In addition there is a thrust washer (again with splines) that goes on the arm at virtually THE SAME TIME as the lever. What this means is that you need to align the splines of BOTH parts to the arm before you try to push the arm through - but only being sighted on one of them! Not tricky enough? Okay: as the arm is pushed through the housing and (before it even reaches the lever and spacer), there is a risk that it pushes against the 'nut end' bearing which in turn dislodges the seal - all out of sight now because the lever is in the way.....</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9DEBopJJNyqfdFYRgXqbZCx7HcgKExLdPX5u7PHqCxmjaQOEqgavSoiZvCLpkY2mEEfUAn9cyNjyuPDOz9xegqNbBhpcxSbACAi6MRFc8jhlNRxNInaJCCBLfz4wPLXPk6e0AY3B3rkEjzbJlAUOwGrSfiLZwb9fdrH71LSgtF9HMSAsigj7Ugw/s1212/thrust.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="753" data-original-width="1212" height="249" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9DEBopJJNyqfdFYRgXqbZCx7HcgKExLdPX5u7PHqCxmjaQOEqgavSoiZvCLpkY2mEEfUAn9cyNjyuPDOz9xegqNbBhpcxSbACAi6MRFc8jhlNRxNInaJCCBLfz4wPLXPk6e0AY3B3rkEjzbJlAUOwGrSfiLZwb9fdrH71LSgtF9HMSAsigj7Ugw/w400-h249/thrust.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">6 = suspension lever, 7 = thrust washer, 8 - seal</span></td></tr></tbody></table></div><div><span style="font-family: arial;">There is a right and a a wrong way to fit the spacer (aka 'thrust washer'). The manual says it should be fitted so that 'the flat face is against the roller bearing". I couldn't work out what that meant but, the spline section does not go all the way through the thrust washer. On my car, when I removed the parts, the splined side was against the lever - so that's how I chose to refit it. </span><span style="font-family: arial;">I cleaned up the splines with a wire brush and applied a small yellow mark to the first tooth of the splines on the lever and spacer, and to the equivalent groove on the end of the arm. </span><span style="font-family: arial;">The thrust washer is meant to sit inside the rim of the seal - so that it presses on the bearing beneath. </span><span style="font-family: arial;">It was still VERY fiddly to aline the parts up and took several trial-and-error-attempts. </span><span style="font-family: arial;">The sticky grease helped.</span></div><div><span style="font-family: arial;"><div style="font-family: -webkit-standard;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBzQk0J9VhTvch9JJvwZVzSdtcVXzuA7zZlzzeOoX62IxbqNnVvl5swMjRNU696Gr1b34PYMFn7e5K0za0szMMWy9n3yXmCRQeYE1rNQcfcayJkCRTgcQs5Gw-IPVUpZpi0-DQr0V_1JWP-XbssaRDBJOb2Y0tPYuo4r9BP8dIdO8JlBXxt0zCAw/s960/186501595_135373801971531_4499375392495732267_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="960" data-original-width="720" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBzQk0J9VhTvch9JJvwZVzSdtcVXzuA7zZlzzeOoX62IxbqNnVvl5swMjRNU696Gr1b34PYMFn7e5K0za0szMMWy9n3yXmCRQeYE1rNQcfcayJkCRTgcQs5Gw-IPVUpZpi0-DQr0V_1JWP-XbssaRDBJOb2Y0tPYuo4r9BP8dIdO8JlBXxt0zCAw/w300-h400/186501595_135373801971531_4499375392495732267_n.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Upper arm thrust washer in place. <br />You can just see the splines on the side facing the camera<br />(Photo by Deesse Bombe)</span></td></tr></tbody></table></div><div style="font-family: -webkit-standard;"><span style="font-family: arial;">When the splines DO line up, firstly the thrust washer slid onto the arm, and then the arm end started to slide into the lever. Then it all stopped. </span><span style="font-family: arial;">At this point, the fatter machined part of the arm had met the bearing and the arm was a tight fit. A bit more shoving got the arm a little further through the bearing, spacer and lever - but not quite enough of the way through the lever to get the nut on the end to pull it through.</span></div></span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-FD4dfcxGuc2SQJUp6e38iW4RKShINBLuMW5YzddGG6DgE-Uq32_hrOO4xBsJwnBgSK6yy_s0U1bm1xTvpK-_yrKfu1ptbkm4AnDA0N4FJG75IpagAPs6paOMGqcFAvXhD_NFActvNOwclShuT10ICha0mD9YtzCHP67C8DZqzeD4Bo4b91TUNw/s960/186508347_135374235304821_4783394194088660754_n.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="960" data-original-width="720" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-FD4dfcxGuc2SQJUp6e38iW4RKShINBLuMW5YzddGG6DgE-Uq32_hrOO4xBsJwnBgSK6yy_s0U1bm1xTvpK-_yrKfu1ptbkm4AnDA0N4FJG75IpagAPs6paOMGqcFAvXhD_NFActvNOwclShuT10ICha0mD9YtzCHP67C8DZqzeD4Bo4b91TUNw/w300-h400/186508347_135374235304821_4783394194088660754_n.jpg" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Threads emerging through the Lever<br />(Photo by Deesse Bombe)</span></td></tr></tbody></table><div><span style="font-family: arial;">There is a trick you can use here though. Although the nuts and socket sizes for the top and bottom arms are different, the thread sizes are the same. The bottom nut has an extended, thinner end. You can use a bottom arm nut, turned over, to begin to get some purchase on the threads of the top arm. (I'm assuming here you didn't bugger up the bottom arm nut removing it, or have a new bottom nut to hand). </span><span style="font-family: arial;">Once you've managed to turn the nut a few times, you can fit the proper top nut and continue from there. The torque settings for the nut are given in Operation DX.410-3 in Manual 518. When you are sure you are happy with the fit, torque and movement of the arm, don't forget to bash the edge of the nut over to stop loosening up.</span></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhectp8rxDXs3gV5k4MoO6wAWC7KxEMFm8JTj8svQQHQCcQ4MeWBCeLqELx_zq0sj9ot5y-ETM6hM2tdrguS-Q3vNO1tupOXMh15qKtrKlFmChZ310dbpCI3vEh3sZ8f7KmB7TgnL3PI-LfXQvFC9yfrZ4peAD4HfFmSXmbo8h6fs49-ZRSfoshmQ/s4032/IMG_5060.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhectp8rxDXs3gV5k4MoO6wAWC7KxEMFm8JTj8svQQHQCcQ4MeWBCeLqELx_zq0sj9ot5y-ETM6hM2tdrguS-Q3vNO1tupOXMh15qKtrKlFmChZ310dbpCI3vEh3sZ8f7KmB7TgnL3PI-LfXQvFC9yfrZ4peAD4HfFmSXmbo8h6fs49-ZRSfoshmQ/w400-h300/IMG_5060.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">A top arm refitted</span></td></tr></tbody></table></div><div><b style="font-family: arial;">Refitting The Lower Arm And Checking And Setting The Castor Angle</b></div></div><div style="text-align: justify;"><span style="font-family: arial;">Refitting the bottom arm is pretty similar to the top arm - but without the added complication of needing to fit the arm through the suspension lever. </span><span style="font-family: arial;">However it is important to pay attention to the bottom arms as the suspension geometry is partly dependent on the fitting of the lower arm bearings. The Citroen DS steering is set so that it has a positive 'castor' (or 'caster') angle'. In short, the bottom hub ball joint is slightly forward of the top hub ball joint. </span><span style="font-family: arial;">'Positive castor' improves straight line stability at high speed and improves cornering. Both desirable attributes in a DS. Ask President de Gaulle.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB-b9MopD6l0140l9jH-znWLPfM8UcSMzJrhneFF5w0IxAXaKhQnVQn87ygVxFQJr9Yb5ctKsy3Soz4AMIhdIqMu_lJPcC8bCYS73V9Mw_CeRySCbHa7CIOx4IZsMmhAPqXJLT5jidvHWiLioGF3i5K5_Mg-t26EYVH_aU72QEz-BRTVwUVfIa1Q/s691/caster.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="630" data-original-width="691" height="365" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjB-b9MopD6l0140l9jH-znWLPfM8UcSMzJrhneFF5w0IxAXaKhQnVQn87ygVxFQJr9Yb5ctKsy3Soz4AMIhdIqMu_lJPcC8bCYS73V9Mw_CeRySCbHa7CIOx4IZsMmhAPqXJLT5jidvHWiLioGF3i5K5_Mg-t26EYVH_aU72QEz-BRTVwUVfIa1Q/w400-h365/caster.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Caster angle (image by 'Summit Racing')</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;"> A DS is meant to meant to have a castor angle of 1.5 degrees. it's not a lot.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhTwZQdXBZoi-WV9xB9EAjcfUwscKpPqD7aEBgkI0NAZ9-E2EIXOUid4ps5_xnOrhQdggjdfqzNlVDhPq1A_2MZJLMr9yclNdb1TOPQ18Vs_xOS3fzv20NOfdZPl92NmpWojDsKsALH3yfgkk6MpNOuPetXi8hdSfa5PYnpZ55QhG-OrQGoIOO1Q/s949/caster%202.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="214" data-original-width="949" height="90" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhTwZQdXBZoi-WV9xB9EAjcfUwscKpPqD7aEBgkI0NAZ9-E2EIXOUid4ps5_xnOrhQdggjdfqzNlVDhPq1A_2MZJLMr9yclNdb1TOPQ18Vs_xOS3fzv20NOfdZPl92NmpWojDsKsALH3yfgkk6MpNOuPetXi8hdSfa5PYnpZ55QhG-OrQGoIOO1Q/w400-h90/caster%202.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">DS caster angle given in manual 518 (1966).....</span></td></tr></tbody></table></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2dCt4dR_FzLRZA-p0M9rNBmG9FstKPi6heAk5QVazM201WNUa6CGQ_HW3hbgVAs4FfsNfXdvsKabHkltG82bf6lfFJynsyuxYnSbqAb1uY25q0fKpWpHNldlWOXupOZDD7rf2i2lITK_Xifuo2kqUA1qgLZnarC1W0IHvWkqX4Icu0QQZ2RLwvA/s1000/caster%203.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="494" data-original-width="1000" height="198" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2dCt4dR_FzLRZA-p0M9rNBmG9FstKPi6heAk5QVazM201WNUa6CGQ_HW3hbgVAs4FfsNfXdvsKabHkltG82bf6lfFJynsyuxYnSbqAb1uY25q0fKpWpHNldlWOXupOZDD7rf2i2lITK_Xifuo2kqUA1qgLZnarC1W0IHvWkqX4Icu0QQZ2RLwvA/w400-h198/caster%203.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">.....and the same from manual 583 (1975)</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Note how manual 518 says this is 'adjustable'.... Adjustment is made by putting a shim of the right thickness behind the cone of the bearing on the arm side of the lower suspension arm. A thicker shim pushes the out arm out further and so creates a greater 'positive castor' angle.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOyF1uR0NZ4Yk6JtosT1ySoTO7lPOhZ2uUTKlFBIuzPZbHNBdd1e_iDGxlgC5k_yJV5FLsFS0FFJ70Qq279AAkdntr0f8qssf49u_Fm4u2Q67GILGuumr0f1-U1ka7rs8AxdJkqCfL29g_Ld9XJr5_QPesSrLca1eWJgqrpBsduU0praZiVWwvxw/s4032/IMG_4986.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOyF1uR0NZ4Yk6JtosT1ySoTO7lPOhZ2uUTKlFBIuzPZbHNBdd1e_iDGxlgC5k_yJV5FLsFS0FFJ70Qq279AAkdntr0f8qssf49u_Fm4u2Q67GILGuumr0f1-U1ka7rs8AxdJkqCfL29g_Ld9XJr5_QPesSrLca1eWJgqrpBsduU0praZiVWwvxw/w400-h300/IMG_4986.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">A caster adjustment shim</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Now.....given that with their hydraulics, Citroen have a reputation for high quality, high precision engineering, I can't understand why different shims are options for the lower arm. Why couldn't they/ didn't they machine all their alloy blocks and the arms/ eyelets so that there was a 'standard fitting'? </span><span style="font-family: arial;">I will need to leave that question there and just accept that Citroen expect you to need a shim of <u>at least</u> 4.6mm but <u>no greater</u> than 7.0mm.</span></div><div style="text-align: justify;"><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaem3CQ8rqZw7iItUH1OoTBcRRZOgb1f1CukYS8AiAIA0sbNq2grba5NxZ8O1HaHkxLrMwncSY05945UMYdLuBzRLvV-eHM9OB1E5Qm-_VlBuhDmhaDnlEtD4J-_a62Y1ogS6MC1gFZGcN5T-nJIExxrQlCkk2md-iwzpKqwF9Bn7DZta5pfnvfg/s447/shims.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="397" data-original-width="447" height="284" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaem3CQ8rqZw7iItUH1OoTBcRRZOgb1f1CukYS8AiAIA0sbNq2grba5NxZ8O1HaHkxLrMwncSY05945UMYdLuBzRLvV-eHM9OB1E5Qm-_VlBuhDmhaDnlEtD4J-_a62Y1ogS6MC1gFZGcN5T-nJIExxrQlCkk2md-iwzpKqwF9Bn7DZta5pfnvfg/s320/shims.jpeg" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Shim parts from the Parts manual </span></td></tr></tbody></table></div><div><span style="font-family: arial;">The 'quantity needed' is '?' presumably to make sure you don't assume you need one of each. These are an 'either/ or' thing.....</span><span style="font-family: arial;">I made a note of the thickness of the shim that was fitted to my suspension unit. Out of curiosity as much as anything.</span></div><div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg64TFcWBLrZSTCMbc8cHbAlBnlcMT204Uq24t_3qLipgKkOSBdIT93he38U66J5a7bnZMIMIxwl9yQMgeV08SAuXWdXfetwweZ_3TzHSaLuiZ9E94DCu-797BngVtODwEK3ti7MLlqBx39RO_bCCZSCqWuvB1N12HpyEn-2o3YmKQCAOfMeP4ITg/s4032/IMG_4991%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg64TFcWBLrZSTCMbc8cHbAlBnlcMT204Uq24t_3qLipgKkOSBdIT93he38U66J5a7bnZMIMIxwl9yQMgeV08SAuXWdXfetwweZ_3TzHSaLuiZ9E94DCu-797BngVtODwEK3ti7MLlqBx39RO_bCCZSCqWuvB1N12HpyEn-2o3YmKQCAOfMeP4ITg/w400-h300/IMG_4991%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I'm taking this to be a 6.0mm shim - part D.412-84G</td></tr></tbody></table></div><div><br /></div></div><div><span style="font-family: arial;">I think its reasonable to assume that when the cars are first assembled, the appropriate shim is fitted for each arm to give the right castor angle. So if you take it apart and reassemble it with genuine Citroen parts, it should all go back together and retain the castor angle. Shouldn't it?</span><span style="font-family: arial;"> I will also need to leave that question there and just accept that, when re-assembling arms, Citroen garages were expected to check and adjust the shims to maintain the castor angle.</span></div></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">You will see in the procedure at Operation 410-3 in manual 518, that there are a pair of special tools (1865-T and 1866-T) that serves as proxies for bearings and cones - meaning that you don't need to keep pulling out and and replacing the cone if you find need a different shim behind it. </span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlrsEL0lumWsufAY4OEfqABH14TL7dQ73zluKzo0HtTID94N0lcsYxPqU65_Kt_K6YFVxog81AZgb5jkWwb_7r4qBb4stKVvbhxrlfFJBU4cD-Difu3nDxc6fvqZdPHcv4cCFq7HBjrW6OMe6VnTtNf3h1t6vQ8GfkvZJU1UPJWL_ljjl0QfwjEg/s948/Use%20of%20tool%202321%20and%20bushes.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="778" data-original-width="948" height="329" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlrsEL0lumWsufAY4OEfqABH14TL7dQ73zluKzo0HtTID94N0lcsYxPqU65_Kt_K6YFVxog81AZgb5jkWwb_7r4qBb4stKVvbhxrlfFJBU4cD-Difu3nDxc6fvqZdPHcv4cCFq7HBjrW6OMe6VnTtNf3h1t6vQ8GfkvZJU1UPJWL_ljjl0QfwjEg/w400-h329/Use%20of%20tool%202321%20and%20bushes.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Tools for checking and setting the caster angle</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Once you've selected your shim, then th</span><span style="font-family: arial;">ere is then </span><u style="font-family: arial;">another</u><span style="font-family: arial;"> special tool (tool 2321-T) that has two parts that fit into the ball joint eyelets of the two arms and so is used to check what castor angle it gives. The tool does this by measuring the offset of the ball pin eyelets. </span><span style="font-family: arial;">The correct value needs to be between 24.75mm and 25.25mm. That's just 0.5mm tolerance.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjksGWFpMmUxDKeGhvUDYCP6JQPkW8tkdYRVmmzHlu7N6CWCt18TrYD1Aqpa8ijR8-qXU53eoG5EONpqxgS8DsLhZ39kUtL7ag-ywQndWw3t6nNj1Uoflk7l3YkRtmgDY-yF15jwrepfnkfzOCskLybTuh18uzB_CTxS_aFFIaj91LnRf8tDnplIw/s683/2321-T.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="683" data-original-width="544" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjksGWFpMmUxDKeGhvUDYCP6JQPkW8tkdYRVmmzHlu7N6CWCt18TrYD1Aqpa8ijR8-qXU53eoG5EONpqxgS8DsLhZ39kUtL7ag-ywQndWw3t6nNj1Uoflk7l3YkRtmgDY-yF15jwrepfnkfzOCskLybTuh18uzB_CTxS_aFFIaj91LnRf8tDnplIw/w319-h400/2321-T.jpeg" width="319" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Using 2321-T to confirm the offset, and so the castor angle </span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Most DS hobbyists aren't going to have the tools to set and check the castor angle and will just put everything back together. That's what I was expecting to do. I'd seen tool 2321-T (the one for checking the angle) for sale on Facebook back in April 2021 but passed it up. I made enquiries a week or so later and it had gone of course. </span><span style="font-family: arial;">However I knew an old friend and DS expert had tool 2321-T and I asked to borrow it. Not only did they send it to me, but told me I could keep it!</span></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf252y8PsykElSZQW9vaRSOjnprEUEfGcJZ9DDBX8sWeGL8hJmzasiy3IXiOxy97PY1c71erS8YtifJO_4420o7UycE-lOrLM0bgjKIAI2qJv6XROa4a9DwmQoF-cksPhz2-WK586hgzHJ3vKxkCJsZ2VdmrPSsoNGe1Ow09fxne6RKhRa0vZVlQ/s4032/2321-T%20B.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf252y8PsykElSZQW9vaRSOjnprEUEfGcJZ9DDBX8sWeGL8hJmzasiy3IXiOxy97PY1c71erS8YtifJO_4420o7UycE-lOrLM0bgjKIAI2qJv6XROa4a9DwmQoF-cksPhz2-WK586hgzHJ3vKxkCJsZ2VdmrPSsoNGe1Ow09fxne6RKhRa0vZVlQ/w400-h300/2321-T%20B.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Tool 2321-T</span></td></tr></tbody></table><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVtjYyrPoBbJcpIqkgdFaJKYAAGfKjRKXixFpQmQL8V-kdC3h9bh1D4fdOPnDMOxwIEr0SeeS0d-yRj6JzO_OF-45icKnclVuSmUgpUXNKmT28Gzmru3bqOEc9NJm07B9eheWtp1Khos7B9OuvL6QPIBYUaRgvCyYKLEbyuMqsVBL0Q6Etozb2-A/s4032/2321-T%20A.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVtjYyrPoBbJcpIqkgdFaJKYAAGfKjRKXixFpQmQL8V-kdC3h9bh1D4fdOPnDMOxwIEr0SeeS0d-yRj6JzO_OF-45icKnclVuSmUgpUXNKmT28Gzmru3bqOEc9NJm07B9eheWtp1Khos7B9OuvL6QPIBYUaRgvCyYKLEbyuMqsVBL0Q6Etozb2-A/w400-h300/2321-T%20A.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The two parts slot together</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Having reassembled and torqued the lower arm, I nervously fitted tool 2321-T.</span><span style="font-family: arial;"> </span><span style="font-family: arial;">I brought the two arms together......</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9fwH9MCXbd5CvzYjlAqE_pjtSM_uSWdxJAN0ewaCXaPVl8fJgN70wOcYD0XOrY_b5afE8Y8jzpmYp9vNZO6LHINPKs8-mUhMzylnxsp3aJhe7Fax_rsI-1rKp0vkjYfyT8rrK0-KwpWlts3zknbTjley8J9l-9UPpbP3EXYNeNgOM5ET9j3fi7Q/s4032/IMG_5067.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9fwH9MCXbd5CvzYjlAqE_pjtSM_uSWdxJAN0ewaCXaPVl8fJgN70wOcYD0XOrY_b5afE8Y8jzpmYp9vNZO6LHINPKs8-mUhMzylnxsp3aJhe7Fax_rsI-1rKp0vkjYfyT8rrK0-KwpWlts3zknbTjley8J9l-9UPpbP3EXYNeNgOM5ET9j3fi7Q/w400-h300/IMG_5067.JPG" width="400" /></a></div><span style="font-family: arial;">.........so that the tool pieces met and engaged.</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6mf88V6hw2MZZD4hce9BwllHHscn_AfrXgHE78NwwL4UUAVxCO4a0G3LaRgNFtJHYHZYzuILqP1phRtRsaINwcWg7MrfVEh92n8Ytca8_bmvzhTkH9NRztzjiu810JuE1Fbk_vBqMj6pH_wTGWXeSyQHiLS0hpNF-ACztqh3VouVGwuBJY6SrVA/s4032/IMG_5070.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6mf88V6hw2MZZD4hce9BwllHHscn_AfrXgHE78NwwL4UUAVxCO4a0G3LaRgNFtJHYHZYzuILqP1phRtRsaINwcWg7MrfVEh92n8Ytca8_bmvzhTkH9NRztzjiu810JuE1Fbk_vBqMj6pH_wTGWXeSyQHiLS0hpNF-ACztqh3VouVGwuBJY6SrVA/w400-h300/IMG_5070.JPG" width="400" /></a></div></div><div style="text-align: justify;"><span style="font-family: arial;">I took several measurements. Phew! The arms cam up in spec!</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIXNzSYKH95DTCrFB-rhjA_6mV_6Kje7N3m_-IxY7HsmOYFf8uaivlVm8ylOtvDlWkZ6z8Eijr5DoPlnmO5iwqA-5i9c3r_9ebfG6BQw2wRbjwdqw8FiPQ2eOjmU1r0bigVIlBmVRxhukVq7F3rx0YC82Y7Kf-R46FZ39OIrO2D_0M6vjrfaNbSA/s4032/IMG_5065.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIXNzSYKH95DTCrFB-rhjA_6mV_6Kje7N3m_-IxY7HsmOYFf8uaivlVm8ylOtvDlWkZ6z8Eijr5DoPlnmO5iwqA-5i9c3r_9ebfG6BQw2wRbjwdqw8FiPQ2eOjmU1r0bigVIlBmVRxhukVq7F3rx0YC82Y7Kf-R46FZ39OIrO2D_0M6vjrfaNbSA/w400-h300/IMG_5065.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">In spec!</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Buoyed-up by this, I went on and rebuilt the second left hand arm unit. Except this time when I took the measurement, it wasn't in spec. Not by a (relative) long shot....... In fact when I moved the arms together, the two parts of the tool didn't engage in the slot - they overlapped.....</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMiXI30CS445DGD6J17EI7nzy7ild4mqs-2jE6gPdefU_ko2SD3bNe6bB0L747-bvGdxnpo4f-iQ99WMyKwZtpjgF1I4y2Bf6OAJn6UrKlCjbix72BF-1n77Ix3TYNY9dDVTgl2fhcaUJCB5WWLSRVEne1viyuVpWWnnwBKwh2CzZAaoIi752yEw/s4032/IMG_5014.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMiXI30CS445DGD6J17EI7nzy7ild4mqs-2jE6gPdefU_ko2SD3bNe6bB0L747-bvGdxnpo4f-iQ99WMyKwZtpjgF1I4y2Bf6OAJn6UrKlCjbix72BF-1n77Ix3TYNY9dDVTgl2fhcaUJCB5WWLSRVEne1viyuVpWWnnwBKwh2CzZAaoIi752yEw/w400-h300/IMG_5014.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Out of spec!</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I worked out that the arms were about 6.8mm out of alignment - which by an annoying quirk of coincidence.....</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZL3ULMLtOdIgrRURCEb9PqozoVRrfSW9E-wj3QTl0TDDkZUxYe_HILTopjIJCpXTYtWKy4vZgN645GAjQtFi-6zeQ7tnjIZTaswFuSs6KYCjIo9VcWJx6pa3aK6K2I1_Doh_p_9CLm5amgqkC8moWKaR6gxCIz2OfRMSp1Fv4bB2O19dadxEzlg/s4032/IMG_5029.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZL3ULMLtOdIgrRURCEb9PqozoVRrfSW9E-wj3QTl0TDDkZUxYe_HILTopjIJCpXTYtWKy4vZgN645GAjQtFi-6zeQ7tnjIZTaswFuSs6KYCjIo9VcWJx6pa3aK6K2I1_Doh_p_9CLm5amgqkC8moWKaR6gxCIz2OfRMSp1Fv4bB2O19dadxEzlg/w400-h300/IMG_5029.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">A different adjusting shim</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">........was the same thickness as the adjusting shim on that side.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">Analysing the situation, the two halves still aligned, so I ruled out one or other ball pin eye being twisted. I dismantled the arm and re-assembled it several times using alternative new bearings and even trying the old. The measurement still came out the same. I ruled out heating and bending the arm for fear it would weaken it. I ruled out getting another second hand arm as that could also be bent. I ruled out getting a p/x arm as that represented significant additional cost. 6.8mm is not a lot and I could have just lived with it. But knowing the first arm was in spec. made wee want to try a little harder with this second arm.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;">The shims on the two sides of the car were different so presumably were chosen to make the car 'in spec' when it was manufactured. I had to conclude that at some point in it's past, the car had taken a knock or hit a bump heavily. I'll never know. What I did know, was that t</span><span style="font-family: arial;">o get my arms back into spec, either the top arm needed to come out further (adding a shim where there shouldn't be one), or the bottom arm needed to have the shim completely removed - which should not be the case.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNeqCYXW5a9AorzQPlFuVOUXxJjzusEeGci6fEiHrAYgNA084mfafOIlCXI-WJAbybrmCt2tAGgmbOxjWxx34QzFmC4vW30fho-P9gKaXUhVTC4K-dMwJywdcpfVmB7hjBKAsryjaWpSMzrzEjoToI7xIRKeNUtfe7dT6LJ2CngX8mkyJ2ft-GoA/s4032/IMG_5014%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNeqCYXW5a9AorzQPlFuVOUXxJjzusEeGci6fEiHrAYgNA084mfafOIlCXI-WJAbybrmCt2tAGgmbOxjWxx34QzFmC4vW30fho-P9gKaXUhVTC4K-dMwJywdcpfVmB7hjBKAsryjaWpSMzrzEjoToI7xIRKeNUtfe7dT6LJ2CngX8mkyJ2ft-GoA/w400-h300/IMG_5014%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Choices...which arm to reset?</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">I did try completely removing the 6.8mm adjusting shim from the bottom arm - but the trouble then was that too much of the arm stuck out on the nut end and the threads were not cut long enough for the nut to tighten to the bearing. Perhaps that is why Citroen expect a shim of at least 4.6mm to be used? I considered adding 6.8mm of shim to the top arm - but then there might not be enough thread sticking out to screw the nut home. </span><span style="font-family: arial;">In the end I decided to do a bit of both. Using the Citroen shim as a template I had my local machine shop make me a selection of alternative shims.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXseAoHON3DNiUtl29e_uQeUPhpkj2F3zUIVxIqVI3lppPTTfq_2BbLgxq-K0s6K6rr-Fck2qtbL1MUM3uATK_mo38-D5KblwL4n0ujuKQYb2uQ5MavBPoeiYbGzfAAcHhb5DcNDXtXWazCNTzNANVDCm3R6F79E-7eES13G_kbR6g5AjI7uviNQ/s4032/IMG_5247.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXseAoHON3DNiUtl29e_uQeUPhpkj2F3zUIVxIqVI3lppPTTfq_2BbLgxq-K0s6K6rr-Fck2qtbL1MUM3uATK_mo38-D5KblwL4n0ujuKQYb2uQ5MavBPoeiYbGzfAAcHhb5DcNDXtXWazCNTzNANVDCm3R6F79E-7eES13G_kbR6g5AjI7uviNQ/w400-h300/IMG_5247.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">A selection of shims</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">Splitting the difference, I decided to reduce the shim on the bottom arm by about 3mm (which took it just below the minimum shim size but allowed the nut to be fully tightened), and add a shim of about 3.5 mm to the top arm (which still left plenty of thread for the nut). </span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div style="text-align: justify;"><span style="font-family: arial;">I fitted the cones, bearings and seals for the umpteenth time and once again grappled with the splines on the suspension lever. With both nuts torqued up I took a few measurements......the average was 24.30mm - *just* below the bottom spec. threshold of 24.75mm. but considerably better than before.</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEij3oAEAqKA04pnx8dnyQOqxgt6z9XAFbfxf78LGAcH5EAJBVVhTDUFyi-7xWnWLhwNAAT3cVe0BxYyeOJbI9Oy4pXwj0D_Tka1-sJKcDZIVv7O10v6pk4wFJT9wHZIDSXA950DmZexB-Pa8h-51cZZIG148GE82BQOYnPTNnHj7cJhlt2CU7TGtA/s4032/IMG_5255.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEij3oAEAqKA04pnx8dnyQOqxgt6z9XAFbfxf78LGAcH5EAJBVVhTDUFyi-7xWnWLhwNAAT3cVe0BxYyeOJbI9Oy4pXwj0D_Tka1-sJKcDZIVv7O10v6pk4wFJT9wHZIDSXA950DmZexB-Pa8h-51cZZIG148GE82BQOYnPTNnHj7cJhlt2CU7TGtA/w400-h300/IMG_5255.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Close enough!</span></td></tr></tbody></table><span style="font-family: arial;">I concluded that while 6.8mm might be significant in terms of castor angle implications, the fact that the tool ends were still in the right planes (even though the didn't align), seemed to confirm to me that a 6.8mm bend over the length of the arm was unlikely to have a significant effect on the rest of the steering geometry - such as camber. Especially now that I had recovered about 6.5mm of that bend. I decided I had done as much as I could and left it at that. </span><span style="font-family: arial;">So that's it - job done.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;"><b>Final Thoughts</b></span></div><div style="text-align: justify;"><span style="font-family: arial;">Tool 2321-T is part of the standard DS workshop tool board - which I take to include those tools that, (of all the many, many available) are used most often. So if checking was a frequent or routine activity, then maybe it was quite common to find that the castor angles of cars was out of spec? Maybe lots of Ds driving around have bent arms?</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLaH4_YAAmKZPfne4F0ARJrNZNnH4MFXvFPKkYYXHTnwB2ezj5CuTNRbhGFvH99EINxIZE-1E4C1105is9I1J5AxrhXExZ0QidmeUhRLznX2IrHTk-WTiS0CeZIdhHbkMEMABgJb2VMKnSfgBRfK8_hzW8TQZ4QmGM_q8WoR8wdtLqsHdmksIYPw/s958/96157917_984073228657358_4785739263155109888_n%20copy%202.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="592" data-original-width="958" height="248" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLaH4_YAAmKZPfne4F0ARJrNZNnH4MFXvFPKkYYXHTnwB2ezj5CuTNRbhGFvH99EINxIZE-1E4C1105is9I1J5AxrhXExZ0QidmeUhRLznX2IrHTk-WTiS0CeZIdhHbkMEMABgJb2VMKnSfgBRfK8_hzW8TQZ4QmGM_q8WoR8wdtLqsHdmksIYPw/w400-h248/96157917_984073228657358_4785739263155109888_n%20copy%202.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Workshop tool sets</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">All said and done, I've ended up with arms that are in a better state than when I removed them but it was quite a journey, not without expense and with a few worrying times. </span><span style="font-family: arial;">Had I had the benefit of tool 2321-T available when I first removed my hubs, I'd have checked the arms for 'true' there and then. I assume I would have found the left hand unit wanting and, needing to obtain an alternative, would probably have gone straight down this replacement route. Which would have saved me a lot of effort, and saved you the time taken to read this post.</span></div><div style="text-align: justify;"><br /></div><div style="text-align: justify;"><span style="font-family: arial;"><div style="font-family: -webkit-standard;"><span style="font-family: arial;"><b>Footnote:</b></span></div><div style="font-family: -webkit-standard;"><span style="font-family: arial;">I said earlier in this post that there was an alternative to all this work. If you don't have the facilities or the confidence to do this - or simply can't be bothered and have deep pockets - then you can get replacement arm units on a 'part-exchange' basis, whereby you swap your old arm units for ones that have already been rebuilt (and hand over money of course). In this case, the units are rebuilt with modern, easily obtained bearings. This necessitates machine both the arm part and the alloy body part to take these new bearings. The usual part suppliers offer these replacements. They are not at all cheap and prices vary. That might mean that there are several sources for these rebuilt arms and that attention to detail/ quality varies. Citrotech is a respectable and trusted Dutch company not only selling but rebuilding parts to 'as new' condition.</span></div><div style="font-family: -webkit-standard;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAzQjXFVey5VdiCxuBkBPhoUPteXedwycoSjaGEVVvlBSPUynQ5GxEl0Dj3BeEpZ-Vol_lkMDjFkN3q0A0FOlyqkYGlglog1gK8KoAf_LAQelplEiGW3Cc3U-6sJ8Smf0H3ilkC12bcXpfs3iwkNpIIrBChHGO1JI5wmAtrjxkfoX0JOMWxAUSEg/s1026/citrotech.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="614" data-original-width="1026" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAzQjXFVey5VdiCxuBkBPhoUPteXedwycoSjaGEVVvlBSPUynQ5GxEl0Dj3BeEpZ-Vol_lkMDjFkN3q0A0FOlyqkYGlglog1gK8KoAf_LAQelplEiGW3Cc3U-6sJ8Smf0H3ilkC12bcXpfs3iwkNpIIrBChHGO1JI5wmAtrjxkfoX0JOMWxAUSEg/w400-h240/citrotech.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">These arms have new, modern bearings fitted</span></td></tr></tbody></table></div><div style="font-family: -webkit-standard;"><span style="font-family: arial;">They have a short video showing the process of re-cutting the suspension parts for new bearings. You can see that the tapered face of the arm is cut back. The video is available </span><a href="https://www.youtube.com/watch?v=eKBgE2_2htc" style="font-family: arial;" target="_blank">HERE</a><span style="font-family: arial;">.</span></div><div style="font-family: -webkit-standard;"><span style="font-family: arial;"><br /></span></div><div style="font-family: -webkit-standard;"><span style="font-family: arial;">My friend Peter went down the replacement route and - as seekers of DS knowledge - we both agreed it would be interesting to see how his arms measured up for spec. using tool 2321-T. And the answer is that not only were they 'notch-free' they also both came up on spec. I should have looked more carefully to see whether Citrotech are re-using old top arm nuts or - as I suspect - have had some more made up.</span></div></span></div><div style="text-align: justify;"><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;"><br /></span></div><div><br /></div><div class="separator" style="clear: both; text-align: center;"><br /></div><br /><div class="separator" style="clear: both; text-align: center;"><br /></div><br />Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-70170659798168562892022-08-30T21:33:00.001+00:002022-09-28T22:26:46.699+00:00Painting The Engine Bay<div style="text-align: justify;"><span style="font-family: arial;"> Well, I finally got there! I finally got round to painting my engine bay!</span></div><div style="text-align: justify;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQLMHX6oA96aUVJhu5cd1vUGJmqvuvVSOTLkgTAyABQ0_wjMnK5FRlYBr0WOvh71f5t4UNsEAhCgF0uY6DMYLanIy9dpVMbQT5v1fl4kbwTHuSgRjRGb2wuUBD4KQ-bgNHqrEwhj4JXzkQq4bZQYtaCMI0hBeJzcO_kKlpa4gObMk7Ls6F0Q0J6Q/s4032/Second%2015%25%20coat.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQLMHX6oA96aUVJhu5cd1vUGJmqvuvVSOTLkgTAyABQ0_wjMnK5FRlYBr0WOvh71f5t4UNsEAhCgF0uY6DMYLanIy9dpVMbQT5v1fl4kbwTHuSgRjRGb2wuUBD4KQ-bgNHqrEwhj4JXzkQq4bZQYtaCMI0hBeJzcO_kKlpa4gObMk7Ls6F0Q0J6Q/w400-h300/Second%2015%25%20coat.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">I can hardly believe it!</span></td></tr></tbody></table></div><div style="text-align: justify;"><span style="font-family: arial;">For years, this had been a key milestone for me as it would mark the turning point between dismantling the car, and reassembly. Many was time I had thought back to when I'd first 'rediscovered' my car in the farm barn back in September 2014. This is what had faced me.</span></div><div style="text-align: justify;"><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dw15fjkfxS_VPxYAUF8yseYGP_mg0PHAvFKCyJzbETsNNGyZ6hXv5QWZiu1XkNJPgCLJ7ZEPc1gqfanhuw-KQ' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div><br /></div><div style="text-align: justify;"><span style="font-family: arial;">My rose-tinted plan then had been to get the car to start, hose the engine bay down with a pressure washer and then merrily drive off into the distance. The reality was that there was a lot of grease, grime, rat shit and surface rust. And so the engine came out....All of this saga forms the earlier posts in this blog.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgByOiU-hiPmFQKB5C2xfne-OizcX_Y2Z7Fx_gCvOH5LPSqjBa75Ogd_Ei6relPs-wV1ViXGeca-krLT6y774z72kZ89s4vJBfXWT9UCBYC2vktAUt2-_N3RORBET0loLLq5edyYFHmgBpbUMWGTuZbIg1cT4ODCBdgcts1UKP0wIRTFKacEmuYdw/s1632/Engine%20bay_Jan%202020%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1224" data-original-width="1632" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgByOiU-hiPmFQKB5C2xfne-OizcX_Y2Z7Fx_gCvOH5LPSqjBa75Ogd_Ei6relPs-wV1ViXGeca-krLT6y774z72kZ89s4vJBfXWT9UCBYC2vktAUt2-_N3RORBET0loLLq5edyYFHmgBpbUMWGTuZbIg1cT4ODCBdgcts1UKP0wIRTFKacEmuYdw/w400-h300/Engine%20bay_Jan%202020%20copy.jpg" width="400" /></a></div></span></div><div><div style="text-align: justify;"><span style="font-family: arial;">But now everything, including the scuttle area, had been stripped and de-rusted and was just begging for fresh paint.</span></div><div style="text-align: justify;"><span style="font-family: arial;"><div style="font-family: -webkit-standard;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWo_1tG2bKCy1ITGOKg_asGmm9PIwM6FvtEEkxQWi3JHKUe93dUmyEYmIAorVWc9Lld3xIfyXBl9zMJDdj8RuyVD-Pk04JqgacVSm6rZAEUCcfHssG4_fjZXPQEmaYkHy2BI_PS7JsfJYgw035HZwGput9VFTxQU12lh2yVaid5K-aAT-VVy_X0Q/s4032/Phosphoric.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWo_1tG2bKCy1ITGOKg_asGmm9PIwM6FvtEEkxQWi3JHKUe93dUmyEYmIAorVWc9Lld3xIfyXBl9zMJDdj8RuyVD-Pk04JqgacVSm6rZAEUCcfHssG4_fjZXPQEmaYkHy2BI_PS7JsfJYgw035HZwGput9VFTxQU12lh2yVaid5K-aAT-VVy_X0Q/w400-h300/Phosphoric.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">All prep-ed</span></td></tr></tbody></table></div><div>However a little more patience was needed......</div><div><br /></div><div>I had been using a compressor and air tools as part of the welding on my car. I had recently chosen a compressor with the best CFM value I could afford with spray painting in mind. But now I was finding out all about 'dirty' air from the 'mig-welding.co.uk" site, and how it can run a paint finish. I won't go into all the details but part of the problem is dust sucked into through the compressor, part is water which condenses as air is compressed and, as I have an oil lubricated compressor, part of the problem is oil particles in the air. </div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhs78t5XCv6sPZI10e9EASznbYfIsQl7gQtJGBFxqEvUamV5p-pN3MDueeJ-0lFp6aI3DY2eBJDsvZ4KnUs1ZzgR6-aWmAcsOk1s6ogl9SlVNGV_RRrOn9EbWNIApT2B1OZJmOz8dxvE9Gbu3xyVpDV58JYFFatJd3n0kis65pihcSVOX6z3keWbQ/s900/microblistering.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="695" data-original-width="900" height="309" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhs78t5XCv6sPZI10e9EASznbYfIsQl7gQtJGBFxqEvUamV5p-pN3MDueeJ-0lFp6aI3DY2eBJDsvZ4KnUs1ZzgR6-aWmAcsOk1s6ogl9SlVNGV_RRrOn9EbWNIApT2B1OZJmOz8dxvE9Gbu3xyVpDV58JYFFatJd3n0kis65pihcSVOX6z3keWbQ/w400-h309/microblistering.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">'Micro-blistering' used by moisture in spray air<br />(photo by mig-welding.co.uk)</span></td></tr></tbody></table><div>It would particularly be a problem for the finish on panels. Perhaps less so for a chassis, but what not aim for the best finish i (personally) could get? Taking a lead from the MIG welding site, I set up a filtering system between my compressor and my planned spray gun. The principles are explained <a href="https://www.mig-welding.co.uk/air-system.htm" target="_blank">HERE</a>.</div><div><br /></div><div>In my case I bought a relatively inexpensive triple stage filter regulator, plus a range of fittings from a plumbing supplier to join it to copper piping. The filter was capable of producing 'breathable air'. Handy if I wanted to spray with 2 pack and needed to 'suit up'.</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb4P5Iz1Aqtq-mVxMBd62c6Kc-6y97X0Cp9dZ2V7sz3FE2pdvFbMgMh4wOjEnfgMofQmt95I1eVklYCBlDmSaYNiCoPzS9WoSxrvwQDy3BTP3U9F1kTPyorK9jDtez34xnw8GxSPeyB8pGl3n5YsWAh1SHnzdvNw3G-gNLQdfyi1DaNv6hbTu-tQ/s4032/IMG_4938%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb4P5Iz1Aqtq-mVxMBd62c6Kc-6y97X0Cp9dZ2V7sz3FE2pdvFbMgMh4wOjEnfgMofQmt95I1eVklYCBlDmSaYNiCoPzS9WoSxrvwQDy3BTP3U9F1kTPyorK9jDtez34xnw8GxSPeyB8pGl3n5YsWAh1SHnzdvNw3G-gNLQdfyi1DaNv6hbTu-tQ/w400-h300/IMG_4938%20copy.jpg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Particulate filter and fittings</span></td></tr></tbody></table><div>My garage was going to double as a spray booth. I rigged up a run of copper pipe from one side of my garage to the other - including a couple of drop legs for removing moisture along the way.....</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-MKtOl-UxL-MPBZYqn6cFxhXN9CyX8LH9HDPHmYBQSPEmq-pgamhrKUwELU9_OhSxDmT3pIVCV_aZ4K9U0YYBbJisw-jqzwy44a2-NLsrGjOR4LQSrJTJ5PUUupjZH4r2o994myMrR7TSDOMQ8lLpkzkRZimtXumMQjQlQZA5JmnOZ-lYhdhb0A/s4032/IMG_4949.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-MKtOl-UxL-MPBZYqn6cFxhXN9CyX8LH9HDPHmYBQSPEmq-pgamhrKUwELU9_OhSxDmT3pIVCV_aZ4K9U0YYBbJisw-jqzwy44a2-NLsrGjOR4LQSrJTJ5PUUupjZH4r2o994myMrR7TSDOMQ8lLpkzkRZimtXumMQjQlQZA5JmnOZ-lYhdhb0A/w400-h300/IMG_4949.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Mobile compressor with a 'whip hose' link to the wall</span></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNeoiRddPcBIJPg4_U4gJk_s7cjkIgweMZKbD7t0kt60EnkDTPgNuDxPTXjQVZOI2yQ-HpzHKHOIvi3lqhhrsw6BFgU6e2uH6U70r2vAaQdVSyZ88GIh5VeRc5VBNXIjVRhSt03jRMqHtZIkiEDvlrulU94ZLP6I2uNpvrY5OhI6VnQKjFAxd-fg/s4032/IMG_4951.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNeoiRddPcBIJPg4_U4gJk_s7cjkIgweMZKbD7t0kt60EnkDTPgNuDxPTXjQVZOI2yQ-HpzHKHOIvi3lqhhrsw6BFgU6e2uH6U70r2vAaQdVSyZ88GIh5VeRc5VBNXIjVRhSt03jRMqHtZIkiEDvlrulU94ZLP6I2uNpvrY5OhI6VnQKjFAxd-fg/w400-h300/IMG_4951.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Note the gradual slope in the pipe</span></td></tr></tbody></table><div>......all terminating in the particulate filter at the end. It was close to my workshop door meaning i could alternatively spray in there if I wanted to.</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRVm4JviskxPAJz1TlnrsQ_cJFq9E7oA5ctMVgQYzrDeOjrfJgLCmVGuoOjgzADtzkRAI5bEYun20NaIFVKnnMPNTYYd3rAaMvGBK7asMUEHdKgcWpfhbuP56ztFDEaNfdOjPMPWYKCLv4Zd-sRbIg23HmUxP-YeXwMeylY1gNR5uKGZCp-DUC_A/s4032/IMG_4952.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRVm4JviskxPAJz1TlnrsQ_cJFq9E7oA5ctMVgQYzrDeOjrfJgLCmVGuoOjgzADtzkRAI5bEYun20NaIFVKnnMPNTYYd3rAaMvGBK7asMUEHdKgcWpfhbuP56ztFDEaNfdOjPMPWYKCLv4Zd-sRbIg23HmUxP-YeXwMeylY1gNR5uKGZCp-DUC_A/w300-h400/IMG_4952.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">A dedicated air outlet for my spray gun</span></td></tr></tbody></table><div>I used solder and flux joints. partly because I had a load and partly because there was no risk of them loosening up. In hindsight the flux potentially introduces grease and particulates into my air line, but most of the jointing is before the filter and there is only one 90 degree elbow after.</div><div><br /></div><div>In terms of paint, I didn't want a high, 'wet look' gloss finish as I felt it would look out of keeping with the age of the car. I certainly didn't want a matt finish. In fact I didn't want a satin finish either! I wanted something that was more than satin.....but less than gloss! After much dithering on my part, I bought Eastwood 'Extreme Chassis Black' as it was thin and sprayable. To get the kind of finish i felt I wanted, I planned to try mixing 67% satin finish with 33% gloss finish. As recommended by Eastwood, I used their 'Extreme Chassis' primer for consistency.</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNDwsraLGntX-AFAj-yNmiU7nLbfSxpJeZQJe2gvWI9i_IQh8lxE7u3F4rLkdBDzZ8RyZd718xEEckXE3nPYZH3eNlkdyJg4b1RZBUhvatzPxzl7WgFmI-6F4APBOJZf-9HXH0ZU73i3n46q8p3zqUj48m99RJPHHT7qvtj1yiXvKdMXArj5U7iw/s633/eastwood.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="633" data-original-width="555" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNDwsraLGntX-AFAj-yNmiU7nLbfSxpJeZQJe2gvWI9i_IQh8lxE7u3F4rLkdBDzZ8RyZd718xEEckXE3nPYZH3eNlkdyJg4b1RZBUhvatzPxzl7WgFmI-6F4APBOJZf-9HXH0ZU73i3n46q8p3zqUj48m99RJPHHT7qvtj1yiXvKdMXArj5U7iw/s320/eastwood.jpeg" width="281" /></a></div><div>You'll be aware that we had several heatwaves this summer. One of the benefits of this is that it was great weather for painting - with low humidity, lovely dry air and quick paint drying. For a while I'd been scavenging and saving polythene sheet and crudely lined my garage walls and floors with it, using duct tape to hold it up wherever I could. I went back the garage the next day and it had all fallen down in the heat! That was one of the downsides of the heatwave. It was soon put back up but I had to keep adding more end more tape over the next week or so.</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHPlgOi3KC8Y1dDm9LWKXlGIoOpA3H3AEj_Lo15CIdeNp7K14_v-YFuv3ZbL3d88km52ZzxBULagsgrCOLiMuthP_70dHo_zABhek2kBtEleOmPtfls6ruoMhb-IREU7k4CLhsfb_vdFkAHmxkrtPtEACJEtwTTTjY4SAisrwDOUVzskYqPUCCUA/s4032/IMG_5121.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHPlgOi3KC8Y1dDm9LWKXlGIoOpA3H3AEj_Lo15CIdeNp7K14_v-YFuv3ZbL3d88km52ZzxBULagsgrCOLiMuthP_70dHo_zABhek2kBtEleOmPtfls6ruoMhb-IREU7k4CLhsfb_vdFkAHmxkrtPtEACJEtwTTTjY4SAisrwDOUVzskYqPUCCUA/w400-h300/IMG_5121.JPG" width="400" /></a></div><div><br /></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxn114dWDBXbSbBKf8maCbxYuxsK54e6ibZaJhv0JHZSrjs2Dj12E11MYd-5HLoew8vA-xmr4WPUvEMbEkb33n2pf2heF1bUNFie36CtZLNa5jKzSg1TcSmKehjxLWIZbHSvLIAfpgx2bo2IFDist7ohge_5HXHFWnQVVo6lxbd2w8ILtm_k2SXw/s4032/IMG_5122.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxn114dWDBXbSbBKf8maCbxYuxsK54e6ibZaJhv0JHZSrjs2Dj12E11MYd-5HLoew8vA-xmr4WPUvEMbEkb33n2pf2heF1bUNFie36CtZLNa5jKzSg1TcSmKehjxLWIZbHSvLIAfpgx2bo2IFDist7ohge_5HXHFWnQVVo6lxbd2w8ILtm_k2SXw/w400-h300/IMG_5122.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Home made spray booth</span></td></tr></tbody></table><div>I realised that if my compressor was left in my spray booth, it would pull in paint-filled air and soon clog the filter. I'd kind of anticipated this and had left my compressor mobile and so simply set it up in my workshop instead - which was also where I do all my paint mixing.</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikWYZy54nCDdxngTFRVawo6XxQ8_XlHFzrxe1wlLfrW_kuHgqthCWYyFwSDadQo3ea_niGsdRqtgt6K0r-vfvzv8Y0g_TCqmppDJApcAAI6V8VG5MZbxVhJ3uKWLuYqEnG2XNK5s8SX9PcfSfdh4ftEbfkl09b07IgQbsECMqqOSwNSckxEA9NqA/s4032/IMG_5119.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikWYZy54nCDdxngTFRVawo6XxQ8_XlHFzrxe1wlLfrW_kuHgqthCWYyFwSDadQo3ea_niGsdRqtgt6K0r-vfvzv8Y0g_TCqmppDJApcAAI6V8VG5MZbxVhJ3uKWLuYqEnG2XNK5s8SX9PcfSfdh4ftEbfkl09b07IgQbsECMqqOSwNSckxEA9NqA/w400-h300/IMG_5119.JPG" width="400" /></a></div><div>The engine bay was rubbed down using a Scothbrite pad, vacuumed several times and then wiped over with panel wipe. Everything was masked - and then vacuumed again. I applied a primer coat. I was really pleased with what i was able to achieve as a complete novice. </div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzlMmwcHGTQgAmmo70MAQdNliokrxTOWX-nFyBBfvapBnPH_XV_BvWQ5HYJToE5ztpLXWgTGuk4tydj29PFGrlVDqerAL88YZUNgJYBHVR3W8EZPI5Um93QWK3RbFpOITKJoZNmZw9vqchXiUYFu23Dgy-FwBHS0FqJnVUV2Pt34vJqxmTpPbL7Q/s4032/IMG_5155.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzlMmwcHGTQgAmmo70MAQdNliokrxTOWX-nFyBBfvapBnPH_XV_BvWQ5HYJToE5ztpLXWgTGuk4tydj29PFGrlVDqerAL88YZUNgJYBHVR3W8EZPI5Um93QWK3RbFpOITKJoZNmZw9vqchXiUYFu23Dgy-FwBHS0FqJnVUV2Pt34vJqxmTpPbL7Q/w400-h300/IMG_5155.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Primer coat</span></td></tr></tbody></table><div>And when it had dried seam sealed in strategic places before applying a stonechip coating to the 'A' panels near the foot well and to the 'tusks'.</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1AZilGeXWeMslfdmaXh5Mam0yVxCIJbjYoiMMR2kxOr13JFgIRYphQz3f8KApa6rPrf80dvQvq9JYTDbhwsouVNXxZa1EYSZEEBfIWWFO6YPmmmMTJrOY4o2duus6mDylAqInvqP_b1w7o4L-_EXs9xaO7HKKuBKg21pQjGj0ae3r6LOAT2n_6A/s4032/IMG_5141.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1AZilGeXWeMslfdmaXh5Mam0yVxCIJbjYoiMMR2kxOr13JFgIRYphQz3f8KApa6rPrf80dvQvq9JYTDbhwsouVNXxZa1EYSZEEBfIWWFO6YPmmmMTJrOY4o2duus6mDylAqInvqP_b1w7o4L-_EXs9xaO7HKKuBKg21pQjGj0ae3r6LOAT2n_6A/w400-h300/IMG_5141.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Seam sealer and more masking</span></td></tr></tbody></table><div>My first gloss coat was a mix of 67% satin finish paint and 33% gloss. I was pleased with the finish but still thought it was too glossy.</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKRtaW1ZRByHbWnI10op-ZNPnt63y-V-W-weWXxwqoVsNSQM42NdLCgkmgqW-zizf6iGl6bVwXLAj1Vr1XxFP2Kn-_8uPd46LkZKD3VodL0irE3aB_52TXhTFjMki_ckEBNhbB11-w5UH2q-eQVfY4LPH0i0ds395aWmp2KdkUGfHCVPE37k8qrA/s2016/IMG_5159.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="1512" data-original-width="2016" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKRtaW1ZRByHbWnI10op-ZNPnt63y-V-W-weWXxwqoVsNSQM42NdLCgkmgqW-zizf6iGl6bVwXLAj1Vr1XxFP2Kn-_8uPd46LkZKD3VodL0irE3aB_52TXhTFjMki_ckEBNhbB11-w5UH2q-eQVfY4LPH0i0ds395aWmp2KdkUGfHCVPE37k8qrA/w400-h300/IMG_5159.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">First gloss coat</span></td></tr></tbody></table><div><br /></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibTzbvhKsqEdisX2JKRMdiZ8ZcHbY7_RkEaOBBgfQrssMwobLlxufAYX3P42_2EmXuoZwSa-dGc89DaQCHRLYlCmMn2O4fYLh9znzYHUD_-Bpg7DpS9TWuZAoWeFfiJfr71OnyuIeCrbPf2-kE7NH_La5OCes2eU6EFmBag8eRhvRt-0rLdCbs-w/s4032/IMG_5166.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibTzbvhKsqEdisX2JKRMdiZ8ZcHbY7_RkEaOBBgfQrssMwobLlxufAYX3P42_2EmXuoZwSa-dGc89DaQCHRLYlCmMn2O4fYLh9znzYHUD_-Bpg7DpS9TWuZAoWeFfiJfr71OnyuIeCrbPf2-kE7NH_La5OCes2eU6EFmBag8eRhvRt-0rLdCbs-w/w400-h300/IMG_5166.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Happy with the finish but......</span></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuUTylFIACcRo3lzbKksczKCIzMzH3gYjvaLrWCdalCX7Gcgc04kw0g1y7LY39JT62rplKjjTeKVaob4AXkvd4_jaW5EWdd7i8C8US-Cs2aadw2shOQgTviQoRLqhkA-AYEeQy3TSz5T8qvNG3sFh80-GkEn6UuQMzmYAHI3tZrTUerQiSZOQy0A/s4032/IMG_5164.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuUTylFIACcRo3lzbKksczKCIzMzH3gYjvaLrWCdalCX7Gcgc04kw0g1y7LY39JT62rplKjjTeKVaob4AXkvd4_jaW5EWdd7i8C8US-Cs2aadw2shOQgTviQoRLqhkA-AYEeQy3TSz5T8qvNG3sFh80-GkEn6UuQMzmYAHI3tZrTUerQiSZOQy0A/w400-h300/IMG_5164.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">.....too glossy for my liking</span></td></tr></tbody></table><div>There was a lot of rubbing down between coats to key the surface. Plus vacuuming, plus panel wipe. But that also provided thinking time and, for my second gloss coat, I decided to mix 85% satin with just 15% gloss. It was all guesswork.</div><div><br /></div><div>This time I was far happier with the finish. It is still glossy, but definitely not nearly as shiny. And definitely more gloss than satin.</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXNu0I0F5jWANXBzbryv5NToqrSRW4uBn1ybpG88M01dVz0rBlzEV1cBQxATMbE6wHczjRpljLS1ag1ZWeaRYOHq5Ri5uZeB8riTNhtakB5FWJMFb4vj5GTFQ_KoHl1W_iXNitKMQsfD4vGlmnpqsl4DwqeyPtxgr-w19jgQKr4WJOIR4hTUfiFA/s4032/Second%2015%25%20coat.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="3024" data-original-width="4032" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXNu0I0F5jWANXBzbryv5NToqrSRW4uBn1ybpG88M01dVz0rBlzEV1cBQxATMbE6wHczjRpljLS1ag1ZWeaRYOHq5Ri5uZeB8riTNhtakB5FWJMFb4vj5GTFQ_KoHl1W_iXNitKMQsfD4vGlmnpqsl4DwqeyPtxgr-w19jgQKr4WJOIR4hTUfiFA/w400-h300/Second%2015%25%20coat.JPG" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-size: x-small;">Second gloss coat</span></td></tr></tbody></table><div>But I'm a novice - and it's not perfect. It's a complex shape to paint and in places I wasn't consistent with the distance of the spray gun. There are also a couple of places where I didn't pull the trigger fully and I was essentially just spraying air over wet paint. This has the effect of roughening the surface of the paint previously sprayed. But none of these faults are serious and none in the areas that really matter.</div><div><br /></div><div>In parallel to this I've been rebuilding my suspension arms and am looking forward to refitting them, but there are a few pipes and hoses that need to go on first.</div></span></div></div>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0tag:blogger.com,1999:blog-4597517440111518822.post-66206251236990859652022-06-19T20:13:00.004+00:002022-09-26T10:30:23.337+00:00Replacing The Outer Sills - Follow Up<p><span style="font-family: arial;">I finally finished replacing the sealing strip around the front door. These strips crimp the outer black rubber door seal to the door frame.</span></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDoTZDGTpE40FVeVVhY5iuWnpimuqRkrWPc090CEg5Efbr4y2CfZaWJ-YjL7H7L035p-pkmcaHLZIj3kYsAp10TeKRlwCeMmcH5wEGonwbUwd-yygHfzWoDOx1ICJTnrgz04C8zT0EVt3O2DmqATSd2eT4gvxGUKpg5GhCeqhWZeICaVy5pSlRdA/s4032/IMG_5096.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDoTZDGTpE40FVeVVhY5iuWnpimuqRkrWPc090CEg5Efbr4y2CfZaWJ-YjL7H7L035p-pkmcaHLZIj3kYsAp10TeKRlwCeMmcH5wEGonwbUwd-yygHfzWoDOx1ICJTnrgz04C8zT0EVt3O2DmqATSd2eT4gvxGUKpg5GhCeqhWZeICaVy5pSlRdA/w300-h400/IMG_5096.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Rusty sealing strip....... </span></td></tr></tbody></table><div><span style="font-family: arial;">Water creeps up inside these unseen. Don't let anyone tell you they have a rust-free DS if they haven't replaced these!</span></div><div><span style="font-family: arial;"><br /></span><span style="font-family: arial;">It was the UK Citroen car Club's 'D rally last weekend and I took the opportunity to order one of the front door sealing strips from Citroen Classics. </span><span style="font-family: arial;">They are a very awkward shape to post but </span><span style="font-family: arial;">Citroen Classics usually have a stall of parts for sale at the rally and will bring along parts ordered and paid for in advance. It was too good a chance to miss.</span></div><div><span style="font-family: arial;"><br /></span></div><div><span style="font-family: arial;">The crimping strips have a 'W' profile to grip the rubber seals outside the doors and the trim inside the cabin. </span></div><div><span style="font-family: arial;"><p style="font-family: -webkit-standard;"></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="font-family: -webkit-standard; margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyz5Vg1r24VxM3zeR5nX1Iwsfl06z-ZUDPjHY5Jxs9j8uavvHnMLoeef0ZQY1SR40TTKUZetsNl8YJF73R-lXOwSlf8KwZIlj10OFgivMc3mV20Rz36WBTAAUPwHo9KTDA1FhYdNFKfoOAtbhQgjERLHXB7FL9fhWW49t6bPxxaeOknysQisWczA/s730/w.jpeg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="640" data-original-width="730" height="351" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyz5Vg1r24VxM3zeR5nX1Iwsfl06z-ZUDPjHY5Jxs9j8uavvHnMLoeef0ZQY1SR40TTKUZetsNl8YJF73R-lXOwSlf8KwZIlj10OFgivMc3mV20Rz36WBTAAUPwHo9KTDA1FhYdNFKfoOAtbhQgjERLHXB7FL9fhWW49t6bPxxaeOknysQisWczA/w400-h351/w.jpeg" width="400" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The crimping strip is '1' in this drawing</span></td></tr></tbody></table></span></div><div><span style="font-family: arial;">Removing the old section.......</span></div><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-uH-zx6YaZqdrNFtfpWGp4XTKzxvY5a2s3BbntAqNjlyFcuhuF7oICo55T7JKx7zGT3gEyYfM0SKGIdxy24qqmnC0IUGu_FlCJ9SPyUn1VOyMpDSVud8lPZAanb9VB2bMiK2QFL1ZBUcp0BxpUejIiwq0bwygLEOI01FN2Rl3M-n-Rhq7K4lNnQ/s4032/IMG_5097.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-uH-zx6YaZqdrNFtfpWGp4XTKzxvY5a2s3BbntAqNjlyFcuhuF7oICo55T7JKx7zGT3gEyYfM0SKGIdxy24qqmnC0IUGu_FlCJ9SPyUn1VOyMpDSVud8lPZAanb9VB2bMiK2QFL1ZBUcp0BxpUejIiwq0bwygLEOI01FN2Rl3M-n-Rhq7K4lNnQ/w300-h400/IMG_5097.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Cutting through the spot welds</span></td></tr></tbody></table><p></p><p><span style="font-family: arial;">...........revealed quite a horror story!</span></p><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis67RUexmXP8OzD8kbhacoKmy607gT3LdizKksp_PfdYcDpO44wwRyXMyOJVvAw1B1iMopxjjhoTrAMMHeCjpJg_soAExpO6p8PHHR1OsC4GODYuhXy4CEW96LQ_fqyY2ykSTsT8X59tzIEY2OO6M-cqfhfLAwwutpWQMJ0ksy6rrHMu9D5MaROg/s4032/IMG_5100.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis67RUexmXP8OzD8kbhacoKmy607gT3LdizKksp_PfdYcDpO44wwRyXMyOJVvAw1B1iMopxjjhoTrAMMHeCjpJg_soAExpO6p8PHHR1OsC4GODYuhXy4CEW96LQ_fqyY2ykSTsT8X59tzIEY2OO6M-cqfhfLAwwutpWQMJ0ksy6rrHMu9D5MaROg/w300-h400/IMG_5100.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Not what I wanted to see!</span></td></tr></tbody></table><p></p><p><span style="font-family: arial;">Though it turned out it was only really the thin metal crimping strip - the bit I was replacing - that had rotted away. Crumbling pieces of old old dried seam sealant made it look worse than it was and the ridge of the chassis, that the channel fixes-to, was actually in quite good shape once it was cleaned up. </span></p><p></p><p><span style="font-family: arial;">Even though the strip I'd brought was shaped for the curve of the front door frame, some significant fettling was still needed to get them to fit the curve.</span></p><p style="text-align: left;"></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiL_I9MV8sTaLKxXqWGyZZvHKyiItEHMvOXWFmYRekZ7gnf-Juhr3LIFfYTj-aP8ovhwHD0YrBLQGhf-D8hznJ9P2IF39Xxi3mMrc6NQ8v2YcsV9b9TM4k43nvcdEOMGS7_dVfTqjLsQWwBshVnAkKmH8lv0r95P26rhaEeBl694Gk0F9UrQqIFfQ/s4032/IMG_5104.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiL_I9MV8sTaLKxXqWGyZZvHKyiItEHMvOXWFmYRekZ7gnf-Juhr3LIFfYTj-aP8ovhwHD0YrBLQGhf-D8hznJ9P2IF39Xxi3mMrc6NQ8v2YcsV9b9TM4k43nvcdEOMGS7_dVfTqjLsQWwBshVnAkKmH8lv0r95P26rhaEeBl694Gk0F9UrQqIFfQ/w300-h400/IMG_5104.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">The patch doesn't quite follow the curve</span></td></tr></tbody></table><div style="text-align: justify;"><span style="font-family: arial;">Because the metal needs to be soft enough to be crimped, it's quite thin. </span><span style="font-family: arial;">Many DIY car hobbyists rely on MIG plug welding. The problem with thin strips are that they are difficult to plug weld with a MIG without burning through. There are modern automotive adhesives that could be used instead but, with the patch needing help to follow the curve of the door frame I wasn't convinced an adhesive would hold it and decided I would spot weld it - just as I had done with the other sections. </span></div><p></p><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBhz-Bnb4O7_m_OUs_Gi7KGWnmnMEm8GbYzWsPvnfSn7vubVRk_cg0b8uMD0wSPYDCin4Iz43PAGzPPZDlcUAQuKIxuBIdzZ3-_aYR3ntV1xiiisrJv0HmgGqX3EI673YVAM_wKMnu_CMN293-R5nk9PmwUBi_wBtYpfeNWa-yMc1zfpn-2xkItQ/s4032/IMG_5106.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="4032" data-original-width="3024" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBhz-Bnb4O7_m_OUs_Gi7KGWnmnMEm8GbYzWsPvnfSn7vubVRk_cg0b8uMD0wSPYDCin4Iz43PAGzPPZDlcUAQuKIxuBIdzZ3-_aYR3ntV1xiiisrJv0HmgGqX3EI673YVAM_wKMnu_CMN293-R5nk9PmwUBi_wBtYpfeNWa-yMc1zfpn-2xkItQ/w300-h400/IMG_5106.JPG" width="300" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;"><span style="font-family: arial; font-size: x-small;">Paint stripped off and ready to weld</span></td></tr></tbody></table><br /><span style="font-family: arial;">I started welding at the top and forced the strip onto the seam as I went along. It was never going to follow the curve 100%, but I was pleased with the result. I plug welded the bottom part where it sits on the outer sill and it was every bit as tricky as I'de been told - especially for a welding novice like me. However i got there in the end and, w</span><span style="font-family: arial;">ith this past piece done, I'm one step nearer to painting the front half of the car!</span><p></p>Paul Burridgehttp://www.blogger.com/profile/16834322471567145989noreply@blogger.com0