Consolidated fleet thread - Saab going, new Korean porridge in.

[dozeydustman]

No progress report.

Yesterday I awoke with a head full of cold and spent most of the day shivering despite it being a warm day. I don’t feel so grotty at the moment hopefully I’ll get finished.

[dozeydustman]

I filled up with oil and installed the cable. But I have a problem.

Drive isn’t being transferred from the clutch to the gearbox, so either the output shaft of the transfer case hasn’t meshed of I’ve royally ballsed something up fitting the transfer case or when I reassembled it.

[dozeydustman]

Clutch does disengage when pedal is pressed which is relief. Transfer gears whine so I suspect the output shaft hasn’t meshed with the gearbox properly. This means oil out, transfer case back off and order another gasket. 
 

Bother

[dozeydustman]

Having had more thoughts and speaking to a few members of the 205 group on Facebook it may be the output shaft from the transfer case into the gearbox has separated.

This means lifting out the engine and splitting the gearbox/sump assembly to re-attach.

Arsebiscuits.

[Rust Collector]

Sorry to hear it’s giving you bother. If you need a lend of an engine crane then let me know, there’s one sat here in my garage.

[dozeydustman]

Now I have largely recovered from what turned out to be a sinus infection which spread to my middle ear I have ordered a cheap borescope to see if I can sort the Peugeot without having to drop the sump/gearbox assembly. I think the sleeve which joins to output shaft of the transfer case to the input shaft of the gearbox has dropped out somewhere in the sump, or become misaligned.

In other fleet news I managed finally to remove the roof bars from the Hyundai. They were severely seized and required much plusgas and the ugga-dugga gun with a long 6mm hex!

[dozeydustman]

We are at this point again.

 

[dozeydustman]

Poking with a magnetic screwdriver and we have sux-s

 

[dozeydustman]

Splined connector back on but the (new) gasket is ruined. I’m going to have to get some hylomar or similar as a temporary thing. 

I have every other gasket for this engine but the transfer case/clutch housing

[dozeydustman]

Excuse my sweaty man-boobs and psoriasis.

Also a parcel arrived

The clock is broken and the fuel gauge are cranky on the ones in the car, but I’ll make one good instrument panel out of two. The new one is from a diesel and not a petrol so it may read incorrectly.

[dozeydustman]

Oh, and for those of you who have done the clutch on a suitcase in the past, will know there is a special place in hell for the Gaulois smoking engineer who decided this was a great place for a bolt

[dozeydustman]

Had two days of running around in the 205 and it is apparent the new old stock cable I have fitted is a little too long. No adjustment left on the bellhousing pin & bolt so I may need either to fit a new nipple to the end of the cable so there is adjustment as it stretches, or make a new adjuster, which without machine tools may be tricky. Photos to demonstrate this at a later point, I’m currently in a queue to get into the recycling centre!

[dozeydustman]

I went to Portsmouth with son-in-law and we came back with this.

1.1 with 84k on the clock and 11 1/2 months ticket. History is a bit hit and miss and needs a set of boots and a bloody good service but it’s a nice little thing. Seller spent thick end of £700 getting through a test, gave £825.

Traced a bit of a stutter to what I think is a broken spark plug so I’ll get those and all the service items  ordered and changed. As it has been off the road for 2 years+ it’s also running on stale petrol which won’t be helping.

Saab declared SORN and is now on the driveway awaiting its fate. If someone here wants to rescue it, I have a post in shite for sale, pay what I was offered on car take back.

[dozeydustman]

Over the last week I was trying to find the cause of the stuttering on the Picanto.

Possibly the original plus the centre electrodes were very worn, but the misfire persisted once replaced. The old HT leads were knackered and fell to bits once disturbed, again possibly the originals.

New set of leads purchased from ECP but still to no avail, not helped by cylinder 3 lead being faulty out the box and me hastily replacing and whoever scrubbed off the original markings on the coil packs and writing their own on in crayon didn’t help with getting the correct sequence.

Sequence found but weak spark on cylinders 2&3 so I managed to find a complete ignition setup on eBay for £19, swapped the coil for  cylinders 2 & 3, replaced the dodgy lead and bingo we are running sweetly.

It’s quite a peppy little thing. Just need a decent set of boots on it and the tracking sorted, and then  later an oil and filters change.