Engine: D5244: S60 core plug strip down

[Thassos]

Nice piece of Kitchen table engineering there thanks for sharing

There is some mention of a tool to hold the self adjusting mechanism, if your re-installing the pressure plate, or does the new one not need this just the compression tool youve made?

[D5meister]

I think they all come

1) Uncompressed - require compressing at fit.
2) While compressed, Self adjuster needs Resetting at fit.
3) Driven fibre plate requires holding accurately at fit.

Luk who make these clutches, and have a large red WARNING label explaining this.

The tool they recommend is £450 Part No 4000 23710
Or
Volvo do it for £200

[D5meister]

Read up on stainless mig welding. Bought some 308Lsi wire £28 with delivery and vat. and welded this up today - another £600 saved.


Fitted the rear wishbone bushes earlier. topmounts. Ball joints.

Need clutch alignment tool to progress - anyone got a 23 spline 1" plastic one I can buy.

[D5meister]

Today made a dual beam engine brace with box support.



#ordered a clutch plate centering tool today so waiting for that before the big day when I pull the box.

Still dont know what tool for flywheel bolts - or cover bolts -- any takers

[D5meister]

Had a good crack at it today. Made a third hand to enable sliding box out on jack - missing the subframe!

[D5meister]

got old clutch and fly off, got new ones on.


My CORE PLUG was hanging out, that was my leak. Loctited metal one in, added a meniscus on quiksteel around too make sure.

New rear main oil seal - Didnt go very well, managed to fold the lip double, remove, spring was off the back! , then it went in lop sided - had to smack the high side hard to pop it - bit worriied with that unfortunately..


Had to make a centering tool for clutch plate. My flyLock tool worked well.

Precompressor and resetting tool all worked.

Bit tired now.

[D5meister]

Dimensions for a clutch align tool. if anyone needs to obtain or make one.

[savabill]

Originally Posted by D5meister

got old clutch and fly off, got new ones on.


My CORE PLUG was hanging out, that was my leak. Loctited metal one in, added a meniscus on quiksteel around too make sure.

New rear main oil seal - Didnt go very well, managed to fold the lip double, remove, spring was off the back! , then it went in lop sided - had to smack the high side hard to pop it - bit worriied with that unfortunately..


Had to make a centering tool for clutch plate. My flyLock tool worked well.

Precompressor and resetting tool all worked.

Bit tired now.

I think after all that work, I'd fit another seal. It'd be a shame if it leaked. Don't spoil the ship for a ha'peth of tar.

[savabill]

By the way, good write up.

[D5meister]

Hi, I agree - but alas stupidity got the better and cracked on rebuilding.

I will know soon enough !!!!

Lots back now - need to do struts, driveshafts, wishbones, exhaust etc