WITW - Barn-find Final Edition

[homer simpson]

Silly question, never used Febi brake discs on a car, how well do they fair? I'm looking for a set of discs and pads for a friend on his BMW (sorry) but Brembos which I usually fit on most cars are very expensive

[roberto]

ive used them before , spot on
get a price from thingy in germany cant remember

[MikkiJayne]

I haven't used them before, but choices are very limited for the D2 S8 these days and these were the best standard option. The quality looks very good tbh - they are coated on the hub and in the vents so hopefully shouldn't go rusty, although no coating on the back. The friction surface is nicely ground so should bed the pads in quickly. I always use TRW pads in the Brembo calipers as for some reason they are the only pads I've found which actually fit the caliper. Every other brand I've tried is too large and needs the edges grinding down, but the TRWs go straight in, no messing.

Mudflap scar on the lower trim:



Gone



New AC drier



Front panel on, fluids in, and running again



The engine was very reluctant to start since the fuel rail and injectors were completely dry, and I think the injectors might have been a little sticky from lack of use (these are from my grey S8's original engine). It refused to start at all for a while, behaving as if there was no fuel pressure, then started up on 3 cylinders, then the others came to life as the engine warmed up. Once it was up to temperature it was running just fine, but it did have me worried for a while! Lesson learned - get the injectors cleaned if they have been sitting around for a long time.

Slightly short on pics today as I've been rushing to get the FE moveable as a friend's TT's clutch died the other day I have to get the FE off the lift so I can fix the TT which is not going to be a pleasant job - the 1.8T engine is so crammed in to the tiny engine bay and has a ludicrous amount of plumbing. The D2 V8 is a joy to work on by comparison.

[Nick Jones]

Good luck with the TT…….. Hateful things to work on in the engine bay at least. Not done a clutch, but I really didn’t enjoy doing the timing belt on my wife’s Mk1 2wd.

Nick

PS. I invested in one of those cheaply Chinese injector cleaner/testers. For a couple of hundred quid it’s really not bad.

[MikkiJayne]

7 hours in and I haven't even got the gearbox off yet I did the belt on this one and that was unpleasant, but this job may well be the worst thing I have ever tackled. There's nothing on a D2 which even comes close.

[Adrian E]

Originally Posted by MikkiJayne

7 hours in and I haven't even got the gearbox off yet

What's the book time for the job? If it's any consolation any of the later Golf/TT platforms seems to have many jobs that take way too long, and need doing far too often. If anyone asks you to do a thermostat housing/water pump prepare to swear a lot! And have tiny fingers and the ability to see into dark corners to get all the various seals in the right place at exactly the same time.....4 hours labour for that alone

[MikkiJayne]

No idea what book time is tbh, but having spoken to a pro mechanic friend who has done a few of these, the book is apparently wrong Several points it does in the wrong order making them extremely difficult, which I know now having done it the hard way

Since its spoiling progress on the FE, some pics can live here so you can share in my misery.

Airbox and battery out to even be able to see the gearbox from the top



Nearly 9 hours to get this damn thing out. Probably doable in 6 if you ignore the book and have done it before. An S8 gearbox can be removed in half that. I can have the whole drivetrain out in 4-5.



A surprisingly small pile of parts, every single one of which is a total arse to remove





Subframe off, hanging on the struts. The book says to disconnect the propshaft before removing the subframe, whereas apparently if you do it after it is far easier



I cleaned the gearbox. I'm not going mad on cleaning this, but it makes it just a tiny bit less unpleasant if its not covered in oily slime



The chain tensioner is leaking badly which is then dribbling on to everything



I think its fair to say we got every last meter of life out of the release bearing The clutch itself is worn, but not terrible, but the dual mass flywheel is toast so its just as well I'm replacing everything



The TT definitely goes on the naughty list with the D3

[S81]

Is the tt clutch job at risk of turning into a larger job ( ie do a list ) now you have the gearbox out ? ,or will you be able to ignore everything else you see when I'm there

[MikkiJayne]

It has to drive to work tomorrow, so clutch and gearbox and thats it. Anything not necessary to make it move is out of scope. That said, I've not actually found anything critical which is a bonus. The oil leak can be done later when the FE is finished.

[MikkiJayne]

Gearbox about to go back in. Send thoughts and prayers...