What did you do to your rig today?

Please feel free to describe your motorhome, campervan or caravan. (make, model, length etc)
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jon_d
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Re: What did you do to your rig today?

Post by jon_d »

Yes,

This is going to test how well the layout compliments the mechanics.

It might be a case of building a little trolley that straddles the bedframe and supports the gearbox. Unto everything and then roll it free of the engine. Swap the clutch, and roll it back.
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Newcastle George
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Re: What did you do to your rig today?

Post by Newcastle George »

Either that or a trolley jack beneath the gearbox to support it and roll it away from the engine.

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George, Julie, Leonie & Sean - Kotara, Newcastle
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Lance
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Re: What did you do to your rig today?

Post by Lance »

Doesn't sound like the sort of job for a Satdy arvo in the back yard. :(
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Re: What did you do to your rig today?

Post by jon_d »

Lance, having seen George's, his could be done easily. I'm dreading doing mine.


Dot, Terry,

How did the stud welding go?

JD
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Re: What did you do to your rig today?

Post by Mrcoolabah1au »

Sound like a very long terry job a month should do :lol: :lol: :lol:
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Dot
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Re: What did you do to your rig today?

Post by Dot »

The trouble is we have to get the clutch out to get the part # off it as apparently they put several different ones in this model bus.
Jon the stud weld went fine on the first stud, the second one Terry did the weld blob couldn't get to so they decided to drill it out but that wrecked the thread so they had to drill it out further then did the helicoil thing, then the one right at the back had no hope of doing the weld thing so that one was a drill a hole in the middle then hammered in the stud extractor and that got that out. Time to give this job to the mechanic we reckon.
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T1 Terry
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Re: What did you do to your rig today?

Post by T1 Terry »

The clutch release is far too high so either the clutch is very worn forcing the pressure plate fingers out against the thrust brg.... or something has gone a much with the air assisted clutch/hydraulics and it is not allowing the clutch fork/release brg to fully release from the pressure plate fingers.... similar affect to holding the clutch pedal down slightly.
The strange feel with the clutch pedal suggests either the pressure plate has failed or the assist/hydraulics is out of adjustment. All these checks etc require either hanging upside down through the floor or snaking up between the ground/chassis rail/bellhousing and my body no longer tolerates these actions, so I didn't even look, a job for someone with a body less damaged than mine I'm afraid.

The first stud came out text book fashion, the second stud was well and truly jammed in and actually sheared the top of the stud off out of the hole making it too deep to weld a second time. The centre hole on that stud went a tad off line and caught the edge of the thread on the way in but the thread size was already bigger than a 10mm tap.... looks as though that one may have been a problem before. The only fix was to drill it out a size bigger, run a helicoil tap through and fit a stainless helicoil to bring the thread back to the original 10mm size to suit the new studs. the very back broken stud was not in a position I could weld it so George got the job of hanging upside down through the floor and using a Snap On drill guide centre drilling the stud. Unfortunately George broke the drill bit and lost my centre drill guide so while Jerry was here we twisted his arm to make a new drill guide. After a few up sizes in drill size we managed to get it big enough to hammer the Snap On stud extractor piece into the centre of the broken stud and by working it back and forward finally got a full turn either way, then George got the job of screwing it out and tapping all the thread holes to clean them, then fitting the new studs. With the manifold surface ground to get the warp out and new gaskets the whole thing went back together with George swinging the spanners and no nasty noises when it started up, so my drill guide didn't go down the port.... just vanished
So, apart from loosing my drill guide George, a job well done, I'll give you a call when I need work done on the Mazda ;)

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Re: What did you do to your rig today?

Post by Mrcoolabah1au »

Ok sound like your in real trouble now :D
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Re: What did you do to your rig today?

Post by Dot »

clutch002.jpg
clutch.jpg
clutch003.jpg
Here are some pics for you boys
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Re: What did you do to your rig today?

Post by Greynomad »

Uh, Dottie,
:? Have you and The G considered jacking up the radiator cap and replacing everything under it with new stuff? :( ;)
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