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  #81  
Old 9th January 2021, 11:57 AM
MikkiJayne MikkiJayne is offline
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60 times normal speed, I think that's acceptable
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  #82  
Old 9th January 2021, 12:57 PM
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moltuae moltuae is offline
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Quote:
Originally Posted by Conan_the_Librarian View Post
I know it's wrong but I was thinking the Benny Hill Chase theme while watching the video! I'm a bad person arn't I?
Did you spot this bit where she plays along to the tune with a makeshift trombone?

Impressive!


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Last edited by moltuae; 9th January 2021 at 03:34 PM.
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  #83  
Old 9th January 2021, 08:47 PM
MikkiJayne MikkiJayne is offline
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Stupid PS cooler! That's not going back on

No video today as I forgot to take the Gopro mount so back to pictures.

It's had the front level sensor and arm fitted at some point recently. Its the wrong arm, obviously (FE version) Still, at least they tried...



Drain grommets are removed as usual



and just sitting next to the ABS pump, obviously



Cut the heads off the lower rear arm bolts, rather than cutting holes in the floor Thing is, the hole in the floor isn't even in the right place!



Tie rods came out, which is nice. Usually on a car in this state they are seized solid.



Everything simple disconnected, just held in by the top plate



Remove as an assembly - I'll break this down separately, although not much of it is going back on.



Bare, and now I can get to the PS pipes. And clean everything, obviously.



Grot everywhere.



Definitely the worst so far



It looks like the gearbox was dragged around on its sump when it went away to, or came back from, refurb. The pan is bent and distorted.



Shame to treat £3K of refurbished gearbox like this



Oil is leaking from everywhere







Everything in here is either seized, snapped, or loose



Snapped rivnuts are no big deal as they are easily replaced



This earth point is going to be a real stinker to drill out, upside down



The starter cable stud was pre-snapped. This'll get replaced by a rivnut.



The one front panel bolt which snapped



The heat shields are mashed up from the engine and / or gearbox being removed previously. I'll replace these studs.





The servotronic solenoid is looking very crusty, and the green verdigris hints as to why it is intermittent. The rack will need to come out to replace this, which is a shame as I didn't disconnect the steering column before putting the car on the lift



More grot from oil leaks





Its going to take some cleaning, this one...
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  #84  
Old 9th January 2021, 10:29 PM
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It looks like you have your work cut out on this one!

I have a real soft spot for a Murple so I’m looking forward to seeing this all clean and back to its former glory.
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  #85  
Old 9th January 2021, 11:50 PM
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Quote:
Originally Posted by Conan_the_Librarian View Post
I know it's wrong but I was thinking the Benny Hill Chase theme while watching the video! I'm a bad person arn't I?
Aaah... I've got that in my head now! Thanks Mike!!

I've come to the realisation that it's so much easier to take the whole radiator support off the car for access. This video confirmed it.
When I did my timing belt last year, it was such a faf to edge myself into the front of the car with the support leaning off to the side because i kept the aircon radiator bolted to it...

Not to mention it took me two days to do what Michaela does in a few hours!
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  #86  
Old 9th January 2021, 11:51 PM
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Glad to see work starting back up on this!
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  #87  
Old 10th January 2021, 12:04 AM
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Quote:
Originally Posted by 27litres View Post

Not to mention it took me two days to do what Michaela does in a few hours!
Timelaps
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  #88  
Old 10th January 2021, 09:09 AM
MikkiJayne MikkiJayne is offline
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Originally Posted by 27litres View Post
I've come to the realisation that it's so much easier to take the whole radiator support off the car for access. This video confirmed it.
This is one of those cases where it's easier to just remove the stuff than to try and work around it, the same as removing the driveshaft and suspension upright to do the power steering hoses. Sure, its possible to do with it in place, but its much more difficult.

In a case like this where everything was seized then its a struggle to get it apart the first time, but once it's all dealt with it'll be simple next time. The front end comes off my grey one in about ten minutes - the worst bit of the job is disconnecting the PS cooler which is annoying and messy but as I hinted earlier, thats not going back on this one as I will redesign it not to go through the front panel. In later models Audi changed it to connect from underneath so it can swing out of the way, so I shall do the same.
The AC rad just swings out of the way too.

With the front panel on, its harder to get tools straight on to things like the water pump and crank pulley bolts, where finesse is essential. If you round off one of those then the front is coming off anyway to fix it, so better to just remove it at the start
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  #89  
Old 10th January 2021, 09:15 PM
MikkiJayne MikkiJayne is offline
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Some 'interesting' discoveries today, including two new contenders for the worst D2 bodge of all time. The guy who maintained this had a pathological inability to do anything properly.

There are two types of bolts holding the subframe to the car - different front to back. The left hand bracket has a front bolt in it, the right hand bracket has the correct rear bolt. He couldn't even get these right.



Oil all over the cats. No wonder it smoked like a high school disco!



Engine out



The crud is half an inch deep on the subframe, but at least it's not rusted out





I couldn't get the right hand shaft off as five of the six bolts were so tight they broke a spline key trying to undo them. The sixth of course was finger-tight. I left it and figured I'd get the impact wrench on it instead - no bueno with that as it just shredded another spline tool



I thought I'd try some heat on the bolt heads. That didn't go well as I was instantly rewarded with a small fireball when all the oil ignited! Possibly I should have cleaned it first Never mind - the fire extinguisher is always close by



This worked in the end, without catching fire or breaking anything



A big pile of bits!



The cretin hadn't bothered refitting the thermal protection on the wiring harness when he replaced the engine so the sleeving is a tad crispy here and just crumbled apart. I'll fix that later.



Are you sitting comfortably?

Sure?
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Why is the gearbox oil the wrong colour?



Because it's hypoid diff oil In the gearbox

Just... what? This gearbox was rebuilt 20K miles ago, and the idiot refilled it with diff oil, not ATF. I guess here endeth the discussion about these gearboxes being picky about what oil they run on 20K on diff oil without exploding is pretty impressive tbh. I'll clean out as much of this as I can, and probably get the converter rebuilt to clean that out, and then refill with Mannol AG52. I'll run it around for a while to thoroughly mix with any remaining diff oil, and then change the oil again. This should sufficiently dilute any contamination such that it is insignificant. Luckily the Mannol is cheap, assuming I can get any from Germany...

Time to lift the engine and box off the subframe, except the lifting eye is missing. No matter. I have a spare.



Once the subframe was moved out of the way I removed the engine mounts to put it on the separating machine, and wondered why one of the bolts was finger tight. Oh look. He cross threaded an engine mount bolt, stripped the thread and broke the block



Nothing is surprising me by this point. I'll get a better look at this when the engine is on the stand. Its likely it can be helicoiled.



This bolt, along with many others is a; mangled, and b; in the wrong place. After spending 5 minutes carefully cleaning it and contriving an allen key to get it out, I discovered it was only finger-tight. The bolt which should go here is missing completely, and there's a hole underneath where this bolt used to be.



Finally on the separating machine





There is a silver lining to all this, which is that this is my car which I bought for scrap money, and not one of your cars which you had thought was being maintained properly! I would not want to have had this conversation with any of you guys!

Its all fixable, I have parts, I'll just crack on with it and it'll be glorious again Oh, and the PO is not having it back, ever!
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Last edited by MikkiJayne; 10th January 2021 at 09:21 PM.
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  #90  
Old 10th January 2021, 10:37 PM
Ronin Ronin is offline
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Wow, how can these people even go to bed at night knowing they've messed something up this bad? I could not live with myself if I did that!
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