Knocking Noise

[Bodgit-fixit-run]

Brill

Just got the shafts out. Was able to do it without disturbing the hub bearings. Took the whole thing out as one unit. Much simpler just disconnected the driver side carries from the strut and the lower arm. Passenger side was just a case of unfasten from lower arm pull it free. The strut swings far enough on this side not to have to unfasten the carrier. Will post some pickies.

Got the Haynes manual today. It doesn't seem to make any mention of the DMF just refers to a flywheel in the petrol engine section. and then in the diesel referes you back to the petrol. Also seems to think that you can't get the gearbox out without removing the engine as well and this can#t be done with conventional axle stands. Just watch this space.

Oh it also tells you to take it to the main dealer for loads of stuff. Never mind it'l get there

I'm now ready to lower the box but have stoped cos it's dark and I'm working outside. Next installment Sunday. Oh joy.

Have a great time on your travels.

[anchorman]

The Haynes manual I have from the USA is hopeless - full of generalisations and if it borders on complicated it refers you to a dealer.

Even the Toyota manual seems to want the engine out for most things and yet there was a Toyota mechanic on here that confirmed that it certainly doesn't need to for getting the gearbox out.

May I proffer a great big cyber pat on the back for doing this yourself.

You are a star.

[Hoovie]

I fiddle with electrics and bits of trim, but am worrying about changing plugs and oil on my wifes Punto,

so to tackle what you are doing, Bodgit-fixit-run, is totally and extremely impressive

Big Respect

[Bodgit-fixit-run]

I thank you. I thank you.

Wasn't able to da anything Sunday as the outlaws have come up for a few days.

Am going to remove the box tomorrow Will then know for certain if it's the dreaded DMF. Or will I?

[chatman]

I thank you. I thank you.

Wasn't able to da anything Sunday as the outlaws have come up for a few days.

Am going to remove the box tomorrow Will then know for certain if it's the dreaded DMF. Or will I?

Top Job Bodgit...But I would have had the outlaws helping out..Then that gear box would have been out by now....

[bothwell_buyer]

I thank you. I thank you.

Wasn't able to da anything Sunday as the outlaws have come up for a few days.

Am going to remove the box tomorrow Will then know for certain if it's the dreaded DMF. Or will I?

Top Job Bodgit...But I would have had the outlaws helping out..Then that gear box would have been out by now....

heaped one on another then they come in very useful

[Bodgit-fixit-run]

Time to celebrate.

The gearbox is off along with one very burnt out clutch and totally knackered DMF. To say that there's a bit of bluing would be an understatement. Not sure why it got so hot. Never smelt the clutch burning.

Photos to follow folks.

Suffice it to say that is not too bad a job if you take your time and look for stuff that gets in the way. My Home made support beam is fantastic and holding several bits like. the engine and steering rack in place as we speak.

I even had FIL (Father IN Law) helping which he volunteered to do. He did look somewhat worried at times. Especial after he commented about remembering where all the bolts go when I put it back together. I did reassure him with "One or two left over won't be a problem" :D For some reason that perturbed the poor man.

Now I just need to order some bits and it's start putting it back together time. YEY B)

[Bodgit-fixit-run]

Have ordered a new kit it should arrive on Monday watch this space. £550 including delivery from Japtec.

Should be back on the road by next weekend.

Am going to do the timing belt as well. I've got the tools ready so might as well do it.

Does this come as a kit or just the belt?

[Bodgit-fixit-run]

All the parts are here.

I can start playing tomorrow. I'm off this week so hopefully it will all be running again by the weekend.

Just spent all day today getting ready for an OFstead Inspection next week. That might or might not happen as I'm involved in adult education.

I deserve a pint and will probably have one later.

Not got the timing belt yet but that can be got locally with no probs.

Watch this space.

It's not clear in the book. Do I need to locktight the flywheel bolts or anything?

Anchorman. How was the trip?

[anchorman]

The trip was fine thanks. I had 4 days in Ireland

where anchorwoman and myself met up with Robert and his charming wife and then 4 days in Germany where we visited the Mercedes Benz museum and met up with some old work colleagues. Clocked up 2000 miles on the RAV and got over 40mpg with speeds up to 85-90mph.

Wifey is a childminder so I'm quite used to ofsted inspections.......and fire service.........and cops.......etc,etc - enjoy the drink.

Looking forward to seeing your motor up and running.

[Bodgit-fixit-run]

Ok Gearbox is half way on. Had to make up some guide dowels which Are appropriately located. However the Prop bit seems to be out of line and it won't seem to swing into place. Left it for tonigh cos it's peeing down with rain and I'm frozen. Will have another look tomorrow. Am I missing something. How can I tell if the splines are in line? Thats all I can think of at the moment.

Great Photos Anchorman.

[Bodgit-fixit-run]

Just a though.

The new clutch friction plate doesn't seem to have any springs nor did the old one. Both identical as they are oem parts. Surely that then defeats the object of a dmf as this has to take up the load that would have been absorbed by the conventional spring loaded friction plate or again am I missing something here? Could this be a reason the dmf fails?

This might be a Homer moment. Doh!

[anchorman]

Don't worry too much about the prop. The uj's only swivel through 2 planes so it isn't always easy to get them to the angle you want. You can either jack a rear wheel and allow the prop to turn if you can do it safely or split it at the centre bearing and fit it seperately but in this case be sure to mark the flange for correct realignment.

The driven plate has no springs to force the DMF to take up the shock and even if you fitted a suitable clutch plate with springs they would not work as they are much stiffer than the DMF springs.

[Bodgit-fixit-run]

Thanks Anchorman.

I'm not sure I made myself clear. It's the gearbox that doesn't seem to want swing into place. I think it's still lightly mis-aligned. Am about to go out and attack it having had me porridge. Gotta keep warm it's brass monkey weather out there. ;)

Have you notice the 'deliberate' mistake on the tightening sequence on the drawing you supplied?

Two sixes and no five. One normally only misses five out on a firing countdown for explosives. Does this mean My car should go like a bomb when finished?

[chatman]

Two sixes and no five. One normally only misses five out on a firing countdown for explosives. Does this mean My car should go like a bomb when finished?

Your doing a sterling job bodgit..and don't envy you out in the cold...Maybe there's no 5 in the Japanese numbering system ;) ;) ;) so the 5th gear on my car is actually an overdrive for 4th..... :lol:

Not heard that above for a while...well last time was when I was about to blow some trenches on Salisbury plain....then it was just "Fire in The Hole" :blowup:

[anchorman]

Looks like the top 6 will be No 5!

Or maybe you need 2 torque wrenches for that one!!!

Things tend to line up better in the daylight.

Good luck.

[Hoovie]

Looks like the top 6 will be No 5!

Or maybe you need 2 torque wrenches for that one!!!

Things tend to line up better in the daylight.

Good luck.

2 torque wrenches going at the same time??

that will be the wife and the mother in law (no, sorry - that would be 2 talk wenches :D )

[Bodgit-fixit-run]

Looks like the top 6 will be No 5!

Or maybe you need 2 torque wrenches for that one!!!

Things tend to line up better in the daylight.

Good luck.

2 torque wrenches going at the same time??

that will be the wife and the mother in law (no, sorry - that would be 2 talk wenches :D )

Two talk wenches eh! Sounds like my wife and MIL. Or even any combination of my daughters.

The box is now in and the suspension cross member back up. Decided to call it a day cos I knackered and cold. So far only lost one bolt. but found a replacement for that. The Haynes manual is so confusing re the gearbox bolts. I wonder If they have realized that the seem to be variations to bolts holes.

One tip. Look out for the gear selector cables cos they get trapped easily behind the mount. Soon sorted though. Just take the mount off and then refit it with the cables in front.

[Bodgit-fixit-run]

Ok so I'm re filing the gearbox. 3.4litres of transmission oil. Dropped the funnel and spilt oil all over the box. B******x.

Question?

Does the gearbox fill hole also run through to where the prop shaft goes or do I need to fill that separately?

I think they share the fluid but need to check. Mr Haynes is crap on this one too. cos I can't find it.

[anchorman]

No they are seperate (didn't I send you the service sheet?).

This is the gear oil;

........and this is the transfer box;

It takes 0.9 litre of GL5 SAE 90 Hypoid gear oil.

[Bodgit-fixit-run]

Thanks anchorman. Will fill that as well now. Good job I asked.

Don't think I got the service sheet. Could you send it me please.

Started it up for a couple of minutes this pm. No rattle to be heard.

Have made a start on the timing belt. now. The manual says take bumper etc off for this for access. Wot a palaver.

[anchorman]

You'll have to pm me with your email address as it's too big. I will send you timing belt info as well.

[Bodgit-fixit-run]

You'll have to pm me with your email address as it's too big. I will send you timing belt info as well.

Now I see why remove the bumper. Grief it's tight in there. What does the belt spacer below the Cam sprocket do? Or is this a silly question.

[anchorman]

Not sure what you mean!

[Bodgit-fixit-run]

You'll have to pm me with your email address as it's too big. I will send you timing belt info as well.

Now I see why remove the bumper. Grief it's tight in there. What does the belt spacer below the Cam sprocket do? Or is this a silly question.

It's a small spacer held in place by a 6mm? bolt. Leaves just enough space for the belt to travel over the sprocket. I'm assuming it must be something to do with stopping the belt from slapping or something. Haynes manual refers to it as the belt spacer.

I've done a drawing hope this helps

The spacer is coloured red.