Tom's Mk5 (2000) 150s SWB 2.5L 76ps Project

[screechowl]

[quote="""Not sure what you mean about having some thing put on it to speed it up ??-got a picture?I am intrested to know what this thing looks like..if it isnt a turbo"[/quote]

That green filler you've used, will it fill holes in the rear quarter floor?

Its good stuff and sets really hard..Where I have used it is only a temp measure until the finer weather comes and then I get the welder out. I highly recommend the stuff I've used..value for money.

Until the finer weather comes??? You'll be waiting 'til the end of never

Here's what's under my bonnet:



The guy was referring to the thin, silver rod going across the engine....

[Van1968]

Until the finer weather comes??? You'll be waiting 'til the end of never not wrong..looking forward to it getting better though..I suffer from psoriasis this time of the year is worse for me. I need more sunshine...get the clothes off and get radiated

The guy was referring to the thin, silver rod going across the engine....[/quote]
Part of your EGR system...Press your accelerator pedal and as you do this arm opens a flap ("butterfly") within throttle body connected to your rubber air filter hose..I modded my system basically got rid of all EGR related parts/blocked off etc (Page 2 of this thread 3/4 of the way down to see the finished result..some members have cable tied their flaps so it remains nearly half open..I opted for permanent removal with spare throttle body in mind)...then turned the pump up..nice ..lots of members have done it and there is a how to post on it by
MarkM viewtopic.php?f=18&t=3968, a big thanks goes out to him. Topic covers both throttle body mod, arm removal and finally mid range pump mod....give it a go..nothing to loose but everything to gain you won't be disappointed ...

[screechowl]

I think its been done on mine cos she really moves, not like my old one... Nowhere near as noisey either. Except for screeching fanny belt when its wet

[Van1968]

I have been noticing a grind/scrape type noise during the first mile or so of driving especially when the van hasn’t had time to warm up. It happens when either slowing down or when speeding up usually when gearing up and down(from memory second to third-third to second). I have been listening out for it and I believe it’s the axle/diff. Gear change is good and as smooth as one would expect for the year.
Playing on my mind a bit to the point I was awake last night worrying about it. So after a little read on the forum and Haynes I popped to Halfords for some fluid. Before I did I got my carcass underneath the van and undid the plug. I wanted to eliminate the thought of having no oil in there at all…there was, but the amount I had was well below the plug level.
So off to Halfords I went as well as getting a quick grocery shop in!!
I bought a litre for now to top up. The idea is to top up and see how it goes. If all fails I would get a gasket and take the back off for a better look…I have a leak from the seal and my intention is to rectify it. I must point out it’s not a noticeable on the floor leak. It looks like it has been like it for a while. I should have taken care of it when I treated the gearbox to new oil!! I couldn’t get a gasket locally so have to get one from EBay.
Here is the oil I bought, only a £1 dearer than Halfords GL5.

Got this Allen key and it fits a treat, yet to work out its size. I think it’s 10mm

Here is the top up plug. When I undid it and had a look I was convinced the plug had a magnetic end. The reason being I had small what would be described as filings shaped like a very small Christmas tree. I have learned this is normal for wear and tear. (Some gearboxes have them) However, if sludge deposits were surrounding the plug there is a strong indication the pinion bearing etc. is knackered or most certainly on its way out!

A picture of the back showing the leak which I plan to sort out once I get the gasket sorted. It is the only leak I have. Pinion seal is showing no signs of leaks.

I have topped the diff/axle up and it took 750ml before dribbling out which came as a shock as about 1.5ltrs is recommended. Basically the diff was operating half empty (or half full depending on your philosophy) what damage has been done as its slowly leaked over a given time is a question I’m unable to answer. I am hoping none. If I have to overhaul the bearings and change the pinion etc then I will opt for swapping everything for a taller ratio 4.63 (Currently 5.14).
First things first though, see how things pan out with the top up done.

[MinorMatt]

I would have added some axle treatment when topping up

Mine has a square filler plug

[RonTransitmk5]

Love it!
Love it!
Love it!

You still got it?

[RonTransitmk5]

Love it!
Love it!
Love it!

You still got it?

Can you Just minus the 'You still got it? dumb quastion

[Van1968]

I would have added some axle treatment when topping up

Mine has a square filler plug

Thanks for the tip..have you a recomended type/name. I have also read you have tapped a m10 drain plug in your axle...don't suppose you have a picture..location etc..case thickness and best area. I was thinking lowest point, probably have a better idea when I change the gasket..

[Van1968]

Love it!
Love it!
Love it!

Can you Just minus the 'You still got it? dumb quastion

mad sod..keep up the good work Ron

[mealic]

Some great tips and interesting work going on here.Be good to meet up at Transimania.One thing that does concern me though is the fitting of your rear seats.You seem to have all that metal above the floor and nothing to reinforce the underside apart from a few penny washers on the fixing bolts.I feel that a couple of strips of the 3mm plate used on the underside on the bolts securing the seat would have spread the seat load in the unfortunate event of an accident.Also noted that you applied silicone to the screws through the bulkhead etc.Should really have been an oil based mastic as silicone is a friend of the "tin worm".
Most certainly not intendiing to be critical of your project.........................more worried about the safety of your family.

[MinorMatt]

I've used forte treatment in my axle, but there are plenty of others.

With regards to the drain hole... decide where you want it when you take the rear plate off. IIRC you can't tap it right at the bottom, but there is a decent thickness near the middle

[Van1968]

Some great tips and interesting work going on here. Thank you..

Be good to meet up at Transimania....I am hoping to be there and get involved as much as I can. My wife's Birthday on the 24th so I will be chatting to her about what she fancies doing. I haven't had a look at what's on for kiddies..whether camping is allowed..pitches etc,etc. Still early days..the best part is I'm not working I will have a look atposts/threads on past events..I'm sure I will get the answers from there

One thing that does concern me though is the fitting of your rear seats.You seem to have all that metal above the floor and nothing to reinforce the underside apart from a few penny washers on the fixing bolts.I feel that a couple of strips of the 3mm plate used on the underside on the bolts securing the seat would have spread the seat load in the unfortunate event of an accident. thanks for sharing your concerns..I will be honest when I fastened the nuts up..I wasn't happy with the length of the bolts I used for the seat m12x60mm..I plan to use m12x80mm and I still have a 6mm plate left over. As well as using penny washers I plan to use a tapped plate approx 50mmx50mm..thread it on..penny washer then nut...job done.

Also noted that you applied silicone to the screws through the bulkhead etc.Should really have been an oil based mastic as silicone is a friend of the "tin worm". The stuff I have used is not up for the job( peels away too easy) and your quite right..I used the silicone as it was lying around and I was keen to stop the leaks asap...I am still getting water in..not as much, but its doing my nut in..have towels spread along the floor..
Most certainly not intendiing to be critical of your project...No worries on that front your helping me out, that's why I joined the forum to start with..I am always up for a few helpful tips,encouragement,direction and occasional p**s take makes all the work we do worthwhile......................"more worried about the safety of your family". Thanks for looking out for us..

[Van1968]

I've used forte treatment in my axle, but there are plenty of others.

With regards to the drain hole... decide where you want it when you take the rear plate off. IIRC you can't tap it right at the bottom, but there is a decent thickness near the middle

Thanks mate...I'll give it a treatment when I do the gasket...suss out the drain plug then.
Driving the van to work tomorrow..fingers crossed I don't experience the crunch/grind sounds. Plan to travel steady for a couple of miles and see how it goes.

[MinorMatt]

when you make the drain, make sure you have a suitable sealing washer (I like dowty/bonded washers).

If you make the hole a bit bigger than 10mm you could stick a magnet on the end to pick up any metal floating about in the oil

[Van1968]

Hello again! I’ve been tied up with work and family stuff. I have been busy planning work on the van. In particular welding up the patches I filled with filler. Getting myself a canister of argon mix and bits & bats (welding bits and scrap pieces of metal) to get cracking was first on the agenda.
Here is the welding set up. (At the moment I have 0.6mm wire)