Another D2 S8 gets some TLC

[ThisWayUp]

Another minor area that needs some repair is the heat shield on the near side transmission tunnel. I'm assuming this is a job for a rivenut?

[MikkiJayne]

Did you see what I did with this in the murple thread? The other option is a small grab-washer, if there's enough left of the stud to get one on.

[ThisWayUp]

Originally Posted by MikkiJayne

Did you see what I did with this in the murple thread? The other option is a small grab-washer, if there's enough left of the stud to get one on.

Thanks MJ. I'll check that out - seems a nice easy fix. Worst case I suppose I could drill and simply rivet it.

[ThisWayUp]

Thought I'd look at the drains and clean them out..

Slight problem


There aren't any. It seems to be missing.
A quick look reveals I need this.


Added to my shopping list.

[MikkiJayne]

That's novel. I guess someone took the extreme option last time the gearbox came out! I'm not sure I'd bother reinstating it tbh. I'm sure I have a spare somewhere if you really want to though.

[ThisWayUp]

On the positive side it perhaps backs up the idea tha the box has indeed been out. WHen I bought teh car I was told the previous owner did have some work done on it, but there was no receipt.

I poured some water into the scuttle area to see how it drains, and I'm of a mind to not bother repalcing it - it's two less drain bladders to worry about.

My only thought is that the drain arrangement helps stop engine bay fumes finding their way up into the scuttle, so for all the cost of a secondhand one, it's maybe best to get one. It's maybe not too bad by theteime the cabin filters etc seal in position.

[ThisWayUp]

Managed to do a little bit of work today.

Firstly the front calipers were removed. Fairly scruffy looking and braking has never been this particular car's forte. Unsuprisingly the pads are fairly well stuck, and will need a bit of persuasion to get them out, but at least that will be easier on the bench.

I'll send the calipers off to Pro-Calipers and get them refurbished there.

Next up was the PAS pipes...I wasn't looking forward to the fasteners on the pipe clamp at the front arch. It didn't disappoint! After much faffing, and cursing I put down the tools and made lunch. Quite possibly the best thing I could have done. I've been giving this a shot of penetrating oil now and then for a while, but it hadn't seemed to help.

After lunch, I re-appraised the approach and got a 10mm ring spanner onto the top nut, and voila, it came free. Initially I thought it had broken in some way, but, nope, the nut came off. Well chuffed.

This was the result.



I managed to bring the pipes backwards out into the engine bay, which was handy as it saved trying to split the pressure pipe in situ, which had all the makings of skinned knuckles, and sheared things.

On de-greasing and wire brushing I have this:


A bit toast looking, and not long for this world.


The other ends and the low pressure hose look decent enough, and a fairly easy job.

Someone has tried to make them last longer by coating them with some form of black paint.

My consignment of AutoDoc parts are somewhere, but maybe nowhere. Who knows, but it seems painfully slow. Would really like to be re-assembling things to help my sanity. Spending money and still dismantling is always a bit depressing.

In other news I bought the cooler o-ring set. A trip to my local Audi dealer in my currently most depandable car. In fact, only working car. 1 out of 3 is a poor score.



Eurocarparts were doing Pagid front discs for about £43.00 for the pair!
Oil cooler o-rings were £36.00. The world has gone mad!!
The oil cooler is now fitted up again.

I've been pondering what to do with the subframe. It has localised rust at the front and on the seams at the sides. The front I could treat, but the side would be tricky. A bit of me wants to leave it on and repair locally, and the other thinks I should just drop the subframe, and do the lots.

I think I also prefer the idea of re-introducing the engine and transmission on the subframe as a complete unit. Just seems a better and cleaner solution.

I called Mackies this week. A transmission and torque convertor rebuild is coming in at £2,503.00 plus vat. Yikes. Not going to be much spare change when this is all said and done..

On the plus side I think the transmission and brakes overhaul will transform the car. The front suspsension has been refreshed to some extent, and possibly just needs drop links to bring it up to being decent.

[MikkiJayne]

I always worry when a D2 is my last working car. A TVR as backup for the D2 is a whole new level of brave

I can recover that PS pressure hose if needed, by replacing the rusted bit with hose and a suitable fitting. The union actually looks quite good so if you soak that in evaporust for a while then WD40 it should come apart, and then the new fitting can be added. The front pressure hose can be left in one piece that way, and you don't end up with the annoying whine. If you have a competent local hydraulic hose specialist (ie not the monkeys at Pirtek!) then they could also do the same - the fiting is a DIN M16x1.6 60-degree cone without o-ring. Its quite a tricky thing to get hold of.

How are the crimps on the return hose? Those are also quite a common failure point - they leak even when the crimps are still intact, and the hose is a really odd spec so I re-crimp them and then protect the joints with heatshrink.

[Conan_the_Librarian]

Good to see the progress.

[ThisWayUp]

Originally Posted by MikkiJayne

I always worry when a D2 is my last working car. A TVR as backup for the D2 is a whole new level of brave

I can recover that PS pressure hose if needed, by replacing the rusted bit with hose and a suitable fitting. The union actually looks quite good so if you soak that in evaporust for a while then WD40 it should come apart, and then the new fitting can be added. The front pressure hose can be left in one piece that way, and you don't end up with the annoying whine. If you have a competent local hydraulic hose specialist (ie not the monkeys at Pirtek!) then they could also do the same - the fiting is a DIN M16x1.6 60-degree cone without o-ring. Its quite a tricky thing to get hold of.

How are the crimps on the return hose? Those are also quite a common failure point - they leak even when the crimps are still intact, and the hose is a really odd spec so I re-crimp them and then protect the joints with heatshrink.

Hi MJ I've been lucky with the TVR of late. I finished the engine refresh last year, popped some miles on it locally and then used it for a business trip from Glasgow to Peterborough to bed it in. The worst it did was lock me out at Scotch Corner services. Handy when all the tools were in the boot. Spent the rest of the trip with my newly purchased 'break-in' tools in my pocket.

GH77 of this forum will doubtless be along in a moment to regail the story of the TVR setting itself on fire on the way back from an MOT. A dodgy coil pack conenction that led to a misfire and a melted cat. The puff of molten catalyst from the ns tailpipe was quite impressive.

On the PAS hoses I'm thinking they need a complete refresh - I'll drop you a message with some better pictures.

The AutoDoc bits appeaered, which will allow some progress.

I'm storing up an ever increasing stack of parts for sending away for refurbishment:-
PAS Hoses
Calipers
Transmission
Transmission hoses
Wheels - refurb and new tyres (currently has perished DeathSlides)

Financial ruin is just around the corner . I'm clearly the kind of person that feels the need to own a Maserati at some stage.