The Car: Late W reg, V6 24v Auto
The Issue: No forward drive, only reverse, real awfull noise comming from the box.
The Job: Bin the awfull ZF 4HP 20 and replace with a Manual Box!
The Job is NOT for myself, but has been waiting 6 months for this to happen. Originally planned for March this year, its now happening now.
Working space prepared
The car awaiting attention
Needs Out:
State of play after 3 hrs work..
Bumper bracket bolts came out in one piece, cooling fan assey panels unbolted, drive shaft nuts undone, water rad off..
Things to look at Ive noticed so far.
Air Con Doesnt work.
HP Pump needs a set of seals..
..
So, mechanical side first... then we need to tackle the inside, dash out and put in a manual brake pedal and clutch pedal, and plumb in the hydraulic line to the gearbox..
Not much to add but some progress this week.. got the battery box out.. hydraulic pipe work from pump to car off.. lhm tank removed.. autobox ecu and harness to box removed... exhaust pipe to manifold undone etc etc.. subject to drive shafts out im ready for lifting out..
An interesting thing i spotted in the second pic in the centre theres the mounting point for the regulator.. amazingly.. after a quick look at the manual box they have cast the identical bracket mount on the manual box!!!
Some progress today...
We are out! That was not a bad thing to do, the gearbox is very compact, its only favour.. the unit just lifted straight up as the end of the box clears the nearside chassis leg!
So, it was then box off, not before releasing the 16mm x3 bolts to the torque converter..
One down two to go... but they werent all that tight! Thank god! Managed to get at them past the exhaust pipe...
and its box off..
then flywheel off, which to my horror showed up what the "Metalic" scraping sound was when running...
See the marking on the block!.... it doesnt look good..
Allready to put the flywheel and clutch on we find a weeping crank seal..
That ends engine work till we can find one..
So, onto the interior.. and dash out..
The thought on what to do next.. I decided id just move the pedal box forward to work on swapping the pedals and master cylinder bracket..
7 bolts are accessed from in the engine bay.. well two are on the firewall... and 5 are in the scuttle.. wiper assey out the way..
The blower intake cover needs removing to get the nuts off..
Two here and a third under the wiper assy i didnt picture..
And these two further down the firewall that secure a bracket next to the parking brake..
We were then ready after some plug disconnections ready to pull forward..
And heres the pedal pivot bar that i need to work on...
I also needed to remove the heater vent ducts out the way to gain view..
So... Rather alarmed by the scoring thats been going on. Ill need to fit the solid flywheel and do a bit of levering to see if theres any play...
.. if you know, then you be as good as me then!!
