GarytheGolf

Again, a very cold day on Saturday. Decided to do a couple of small jobs, the main one to refurbish the starter motor.

A picture of the starting point:



A bit of a jigsaw puzzle this, here are the items stripped down ready for painting:



Just noted that the top left item is the wrong way around.

The casings painted:



The starter motor reassembled after cleaning and checking all parts and lubricating the bearings.

Weather bad again, only a little done this weekend, Alternator this time.

Before:



Stripped, though I cannot get the front bearing off the shaft, no need to really.

A record of the small amount of work done last weekend, Sunday was a bit wet.

The alternator refurbished and reassembled.

Just read you thread and you have inspired me ,now i cant wait to rip my engine and box out.Keep up the good work.

Thanks for the support, it takes some time, just nibble at the mountain doing a bit at a time.

What an inspiring thread. Just reading around because I'm about to completely gut and redo my clipper, and I have to say your work is impeccable and very impressive! What's your mechanical background?
Keep up the good work; can't wait to see more pics!!

Another little update:

The alternator fitted:





Starting to sort out the gearbox, I have aquired another 5 / 4 + E speed box from a Mk2 with a longer 5th gear which I am going to get reconditioned.

As much as I would like to do it myself, I have never stripped a gearbox, I would not like to put it into the car and find it was not good. I have found a gearbox reconditioning place in Salisbury via a couple of recommendations.

Original 4 speed on left, FM Code Close ratio 5 speed from Mk1 in middle, 4T Code 5 / 4+E speed from Mk2 on right.



The Mk1 & Mk2 gearboxes side by side, notice the differences in the attachments around the diff:







Off to the gearbox reconditioners in the wifes Lupo, which I think will be the next VW classic in years to come.

Unfortunately the gearbox is rattling in idle after only 20K on the clock, its a Polo gearbox, so I am also getting that checked out as well.

Managed to get a whole day on the car today.

Picked up the gearbox from the reconditioners on Friday, saw it in final assembly.



Removed the engine off the engine stand.



The gearbox connection plate installed.



The NOS clutch pressure plate installed.



Had a problem with the new clutch assembly, it seems my 1983 car originally had the 200mm pressure plate installed but only a 190mm friction disc fitted.

The new VW pressure plate and friction disc were 190mm, unfortunately my original release plate for a 200mm did not fit the new pressure plate for a 190mm. Hopefully you can see the difference in the retaining tang position between to the two different sizes. Original 200mm on left, new 190mm on right



So I cleaned my old pressure plate and fitted the new friction disc. It seems, stamped on the pressure plate, it will take a 200 or 190mm friction disc.

Flywheel and clutch friction disc installed.



The gearbox fitted with starter motor, engine and gearbox mounts, everything eventually nice and tight.



The clutch lever will new a coat of paint.







Hopefully tomorrow the engine and gearbox will be going in.

WOW, just read through every page, what an inspiration to all MK1 Golf owners hoping to do a full refurb on their own MK1, i tried to do it but my little helpers forgot to help me, i gave up at the 1st hurdle.

looking forward to the next installment.

Thanks for the comments, much appreciated.

Unfortunately, I cannot fit the engine today due to unscheduled activities and I am away next weekend. It will be a few weeks until the next installment.

I bet they are going to be two long weeks with a lot of itchy fingers.....

Unfortunately, yes, though I did manage to get out and buy some oil for the engine and gearbox.

Gobsmacked with the price of oil nowadays!

Been advised to but part synthectic 10/40 for engine and gearbox. Best for low annual mileage cars.

Couple of weeks on and I managed to get a full day today.

Before putting the engine in I had a few issues to address, flywheel bolts, CV driveshafts and cambelt timing.

I had forgotten to loctite the Flywheel attachment bolts, so the gearbox and clutch came off again to loctite them. Note the gearbox code that nobody can find when it is dirty.



Thought I would clean the CV joints and replen with new grease. Well that went wrong, as I managed to have 4 ball bearings fall out, so I parked the job for another day.

I found that the cambelt timing issue was related to fitting the camshaft sprocket the wrong way around.

For info, both sprockets on the camshaft and intermediate shaft are the same part number and have a dot on each side of the sprocket. The dot in line with the top of the cylinder head should have both the inlet and exhaust valves closed on the compression stroke when the engine is @ TDC.

Having addressed that I was ready to put the engine in.





On the way in.





A few scratches on the way in, which can be rectified later.



Engine in.



Bottom gearbox mount. Still missing an attachment nut, I seemed to have lost it for now, for some reason a fine metric thread.



Offside engine mount.



Nearside gearbox mount



Front engine mount.



Engine covered up.



Finished for the day, it's there somewhere, honest !!

stunning

what gearbox have you ended up fitting??

i need a 5 speed for my diesel but i'm unsure of the code that i need

jellybelly said

stunning

what gearbox have you ended up fitting??

i need a 5 speed for my diesel but i'm unsure of the code that i need

Hi, a 4T from a Mk2 1.8 GL, I believe that it is also fitted to a 1.6 driver. There were 2 4T gearboxes on ebay at the time. I purchased one, here is a link to the other, still a current ebay listing:

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=320659590493&ssPageName=STRK:MEWAX:IT

I will send you a pm on the correspondance I had with the seller on its details.

Quite a bit of work done this weekend, managed a whole day yesterday, Saturday and this afternoon.

Apologies for some of the photographs, camera went a bit dicky, or maybe me. Lost the macro setting for a day.

Car up in the air. My favorite position!



Fitted the exhaust system.



New metal seal and clamps with sealant.



Came across an idea to fit the exhaust spring clamps using a couple of exhaust clamps, works quite well.







The middle box might have to be changed at a later date. Finally found the bottom gearbox mount large fine metric threaded nut, thought I might have to but a new one.



Connected the gearbox linkage, remember 5 speed to replace the 4 speed.




Remember to change the speedo gearbox cog from White to RED, extra tooth for 5 speed, most of them anyway.

Note the little retaining circlip / spring at the end of the drive, this prevents the cog falling into the gearbox when fitting / removing.



Also fitted the clutch cable.







I was able to get my inner CVs cleaned and regreased. Not for the feint hearted this one, thought I was not going to get the bearings back in.

Mucky job, this link really helped me out

Tom's VW Pages - CV Joint Maintenance



Reassembled correctly, notice thin inner race web to fat outer race web.



Lubricated with plenty of grease.





Extra grease in the boot



Glove comes in handy to keep clean.



CVs Ready to fit in the car, just a few bands to fit. Drove me to drink!

Only managed a few hours today, decided to fit the CV driveshafts.





In addition, I am retro-fitting anti roll bars from a GTI to stiffen up the ride. Front brackets installed:

Top work Malcolm - you'll soon be driving it in and out of that garage  

Love it, the only project thread I actually follow.  Keep up the good work

Alex