What's in the workshop this week?

[moltuae]

Originally Posted by Spanker

My thoughts exactly. When I handed the car to Michaela I thought that she was going to just "repair" the car to fix the issues that were reported when it went for a recent service.
How wrong I was. I didn't really appreciate her work ethic when chatting to her about the car. This is more like a restoration. Looks like no stone is unturned. It seems that she doesn't want to let a car out of her workshop unless she was 100% happy with it as if it were her own.

Which is exactly what you need; not just the visible faults repaired but every potential issue dealt with preventively.

Done properly now, it should want for nothing (except an occasional service) for years to come.

Looking forward to seeing it completed!

Will you be able to make it to next year's annual meet Dean, so that we can see this stunning car and its (soon to be) sparkling clean engine bay in the flesh?

[MikkiJayne]

It has definitely turned in to a restoration. I didn't know quite how deep this particular rabbit hole went until I jumped in and found it was more like the Deepwater Horizon I reckon I'm going to have about 100 hours in to this one by the time its done, rather than the 30-40 I estimated before I got it back.

Finally started making a collection of nice clean bits to go back together



250 gloves, a gallon of brake cleaner, a gallon of degreaser, half a dozen cans of carb cleaner and 4 cans of contact cleaner. So far...



Best order a couple of caliper rebuild kits too then. Bugger.

[David's8]

A great way to spend Sunday then MJ! Good effort.
And Mark, Dean will have NO CHOICE except to be there at next Junes meet. We will all want to see the completed work.

[ainarssems]

Pretty much the only seal which wasn't leaking is the rear main, which is a bonus cos its quite expensive!

Would it not be better to change it anyway while in there. If it's anything like 2.5TDI seal which the dealer only sell complete with cover for about £90 but for 2.5TDI you can aftermarket seal only for about £10.

[MikkiJayne]

Originally Posted by ainarssems

Would it not be better to change it anyway while in there. If it's anything like 2.5TDI seal which the dealer only sell complete with cover for about £90 but for 2.5TDI you can aftermarket seal only for about £10.

Great minds... I was looking at it yesterday and thought "that looks the same as this Victor Reinz 2.5TDI seal which I have on the shelf" and indeed it is

[Spanker]

Originally Posted by David's8

A great way to spend Sunday then MJ! Good effort.
And Mark, Dean will have NO CHOICE except to be there at next Junes meet. We will all want to see the completed work.

Yes, Mark & David. That would be the plan.
The intention was to be there this year as well as at a couple of other shows/meets but as you can tell, the red car was in need of some TLC first of all. She drove OK (with the light steering, fluttering engine at lower revs and a noisy exhaust) but she would have made it there and back. But I would have got some odd looks if I had attended.

I did go to AITP in the blue A8 and met Roberto with his white D3, but that was the limit of getting out this year.

So assuming the car makes it through the winter without being written off then I intend to be out and about showing her off with a grin on my face

I'll have a look at next year's meet thread now to see what the score is.

[MikkiJayne]

Not much to photograph so far this week as I've spent most of my time sourcing parts and figuring out solutions to obsolete things like 2002 2.8 radiator hoses Still it has paid off to an extent...





I'm going to quite enjoy reassembling all this lot. Yes, I know there's something wrong with me



Some gearbox pics later hopefully

[tc4332]

There's nothing wrong with you Michaela, just wish that I still had the "get up and go" that I had as a young 'un.
I'm sticking to my woodwork at the moment, just started making a printer stand that won't look too terrible alongside Gwen's oak dining room sideboard. I know, she'll kill me for installing a printer there when they let her out of hospital.

[David's8]

That looks an expensive pile of parts MJ! When a 60cm curved plastic arm for the headlight sensor cost c£50 then that lot could add up to a few quid. Dean must be biting his nails. Look forward to the next installment of pictures

[MikkiJayne]

Ok gearbox stuff - how to change all the output seals on a 5HP24a or 5HP19FLA.

These are what we need - same parts for either gearbox:



01V 409 399 front right
01L 409 399 front left
018 409 399B rear for non-updated flange
SKF 6007C3 bearing from Simply Bearings

If you have the updated flange, the rear seal is 01V 409 399A. This is the difference between the two (018 on the left):



As we know, it doesn't seem to make much difference which you have - they both leak eventually. Given that the updated flange is £250-odd, fit the seal to suit the flange you have.

This one has been leaking for a while!



The flange just unbolts with a T40 torx and slides out. It might need some percussive encouragement! Covered in baked-on oil!



The rear seal is pretty simple - pop it out, press the new one in, bolt the flange back in and top up with oil.

The front right seal is much the same - a T40 bolt in the middle and it slides out.





Pop the seal out



Press the new one in



Use a couple of bolts and a bar to hold the flange still - this works for the rear one too.



The left seal is a little more involved. It comes out with the bearing housing and a shaft which goes through the gearbox to the diff. Remove three T40 bolts and it will push itself out as there is a spring in the end. If you did the right side first, most of the oil will already have drained out.



This is the shaft assembly



There's a circlip to remove to get the shaft out



You could press this out, but I don't actually have a press so I use a vice and a BFH With the alloy mounting flange sitting on the vice jaws and the steel output flange between the jaws, a good whack on the end with the BFH will have the shaft out in a moment.



Both parts separated:



Clean the oil off the shaft and stick it in the freezer. More on that in a bit.

Now you can get to the oil seal and pop that out



Drift the bearing out



The original bearing is an SKF 6007C3. 6007 is a standard size. C3 has larger internal clearances to allow operation at high speed / temperature - perfect for gearboxes.



Clean up the housing in the parts washer, then press the new oil seal in



Flip it over and press the bearing in. This taps in easily with a rubber hammer.



Speedo sensor back in the housing, and the shaft nice and cold (I left it for 2 hours while I did some other jobs) and its ready to reassemble



I forgot to get a pic of the next bit, but with the bearing side down & sitting on the vice, put the shaft back in and with a bit of BFH action it drops back in to the bearing. With the shaft nice and cold it takes much less effort to get it back in than was required to get it out. You could of course use a press instead of a BFH

This is with it pressed back in



Circlip back on and the assembly is complete again



Bolt it back in to the gearbox and its done



I'll re-fill both diffs with oil once its attached to the engine & gearbox jig so its properly level.

Since the gearbox is working nicely, the sump isn't leaking, and the ATF is in good condition, we're leaving that alone for now. I'll just top it up once everything is back together and a full fluid change can be a job for the sucky-pumpy-squirty machine at some point in the future.