Delayed retirement.. again. A conversion...

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citroenxm
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Delayed retirement.. again. A conversion...

Post by citroenxm »

Continued attempts to retire just doesnt happen, and while waiting for some parts for ANOTHER XM, blogged else where, another arrived today safely ...

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.

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Working space prepared

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The car awaiting attention

Needs Out:
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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..
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..

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..

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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...

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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..

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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..
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then flywheel off, which to my horror showed up what the "Metalic" scraping sound was when running...

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See the marking on the block!.... it doesnt look good..

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Allready to put the flywheel and clutch on we find a weeping crank seal..

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That ends engine work till we can find one..

So, onto the interior.. and dash out..

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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..
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Two here and a third under the wiper assy i didnt picture..
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And these two further down the firewall that secure a bracket next to the parking brake..
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We were then ready after some plug disconnections ready to pull forward..
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And heres the pedal pivot bar that i need to work on...
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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...

Hell Razor5543
NOT Alistair or Simon
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Re: Delayed retirement.. again. A conversion...

Post by Hell Razor5543 »

Ruddy hell, you work REALLY fast. What are you on, and where can I get some?

citroenxm
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Re: Delayed retirement.. again. A conversion...

Post by citroenxm »

Thats has all been done in 10 hours split over one week!

Hell Razor5543
NOT Alistair or Simon
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Re: Delayed retirement.. again. A conversion...

Post by Hell Razor5543 »

Still, I repeat my question.

citroenxm
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Re: Delayed retirement.. again. A conversion...

Post by citroenxm »

;-) .. if you know, then you be as good as me then!!

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CitroJim
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Re: Delayed retirement.. again. A conversion...

Post by CitroJim »

Excellent stuff Paul :D

Big job... Watching with great interest.

I take exception to the expression 'awful 4HP20' They are good 'boxes and easy to fix ;) I'd have overhauled it for you...

Which manual 'box are you using?

citroenxm
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Re: Delayed retirement.. again. A conversion...

Post by citroenxm »

It lasted 30k for the current owner...

Its a manual box out of a peugeot 406 as they all seem to come from..

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CitroJim
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Re: Delayed retirement.. again. A conversion...

Post by CitroJim »

citroenxm wrote: Its a manual box out of a peugeot 406 as they all seem to come from..
Excellent! Keep up the good work Paul ;)

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demag
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Re: Delayed retirement.. again. A conversion...

Post by demag »

I'll bring the Synergie up. Probably only take you 10 minutes to do the clutch and gear change cables. :-)

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Gibbo2286
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Re: Delayed retirement.. again. A conversion...

Post by Gibbo2286 »

CitroJim wrote:Excellent stuff Paul :D

Big job... Watching with great interest.

I take exception to the expression 'awful 4HP20' They are good 'boxes and easy to fix ;) I'd have overhauled it for you...

Which manual 'box are you using?
I agree with that Jim. :)
What would concern me is the flywheel rubbing on the block, surely that must be caused by excessive crankshaft end float, as is possibly also the cause of the weeping seal.

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CitroJim
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Re: Delayed retirement.. again. A conversion...

Post by CitroJim »

demag wrote:I'll bring the Synergie up. Probably only take you 10 minutes to do the clutch and gear change cables. :-)
Including a tea break in the middle ;)

superloopy
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Re: Delayed retirement.. again. A conversion...

Post by superloopy »

Enjoying it Paul [emoji6]

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citroenxm
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Re: Delayed retirement.. again. A conversion...

Post by citroenxm »

Gibbo2286 wrote:
CitroJim wrote:Excellent stuff Paul :D

Big job... Watching with great interest.

I take exception to the expression 'awful 4HP20' They are good 'boxes and easy to fix ;) I'd have overhauled it for you...

Which manual 'box are you using?
I agree with that Jim. :)
What would concern me is the flywheel rubbing on the block, surely that must be caused by excessive crankshaft end float, as is possibly also the cause of the weeping seal.
I was waiting for that to be spotted. . XM forum guys think exactley the same.. i need to double check it when i get back there and fit the fly wheel and do a lever check!

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CitroJim
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Re: Delayed retirement.. again. A conversion...

Post by CitroJim »

Gibbo2286 wrote:What would concern me is the flywheel rubbing on the block.
Yes, me too...

It could have been caused by a cracked flex-plate and/or a loose torque converter bolt.

Paul did tell me they did not seem very tight when he undid them - I advised him they are often biblically tight and need a really good spanner to get effective purchase on them. In the past I've always found them very tight...

Definitely needs careful and thorough examination before the new gearbox goes back on and the engine goes back into the car...

citroenxm
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Re: Delayed retirement.. again. A conversion...

Post by citroenxm »

Im pleased though that if this engine is goosed.. i do know of another not a million miles away..

This one has about 150k iirc (could be 138k on it)

Whats a knackered hp20 box worth to someone who can fix it?