FORD HYMER ENGINE GEARBOX AND PROP UPGRADE (FINISHED)

[JIM T]

09/01/2008 TOTAL HOURS WORKED 10

Stared with getting the Hymer up on ramps and then taking the face off, it came off well just 16off self tapping srews for the trim and 6off 13mm nuts and bolts with 2off 17 mm nuts for the rad , (big rad )the electrics had been cut and reconnected with bullet conectors some months befor it was not the cow of a job I thought it was going to be.



Started to dissconnect everthing from the engine ,with the frount off it was a great job and I enjoyed every minute .I then started to take off the exhaurst all 15 foot of it but some German Had welded every joint so I had no choice but to take it off in one length it came out like pulling a elephants tusk stright through the engine bay(pig of a job) .
Next came the engine lift it did not go right from the start I could not get the crain near enough to the engine when I lifted the engine up it fouled the under side of the dash anyway after a few attemps at getting the crain closer it poped out ,it still court on the lip at the top of the opening but no damage (may be I should have taken it out through the bottom like salourman did BUT HE HAD A PIT).

[JIM T]

This is the pump of the old engine, Luke it was a bosch

[rover]

Good work up to now Jim

I take it the new exhaust is in sections then?

Rover.

[JIM T]

09/01/2008) 4 Hours work
Now it was time for the new MT75 gear box I know I have to cut a hole for the gear lever but at the moment it is fouling the crossbeam and I think I need a gear box mounting off a MK5 and I still think the box will foul the crossbeam. The box is a lot lighter than the 4 speed but it was still heavy anyway it's time for my tea so that's it for the day.(5.30 pm) .

[JIM T]

Good work up to now Jim

I take it the new exhaust is in sections then?

Rover.

It better be or the hachsaw comming out

[Luke]

good work jim if you want to weld the mk5 floor in for the correct surround fot the new box stick this is all you need


its the one ive fitted to mine

and that will sit on the floor lining up perfectly

[JIM T]

Did your MK 2 have a dirty great big crossbeam Luke ,and did you have to cut it to get the box back to right position. I think its a trip to the scrappys again anyway

[Luke]

i made a g/box crossmember out of a mk5 one with home made mounting point brackets - i had extra problems with the ifs beam as the V6 engine is deeper than the Di

[JIM T]

LOOK LIKE THE BURNNIG TACKLE IS COMMING OUT

[pete_the_4x4]

like your van

[JIM T]

Ta mate

[JIM T]

10 Jan 2008 2hours work
not much don today I knackered my self up so I only worked in the garage, I took the EGR system off to give me more room when I put the knew engine in. The two bolts that hold the stainless tube on the manifold were over tight so I had to warm them with the gas welder they came off but only after I had hammerd a 9mm ring spanner onto them the rust had taken them down from 10mm thats about it .

[JIM T]

11 JAN 2008 2 HOURS

Started the crossbeam modifications today and they were not too bad .I had to cut a rectangle shape peace out of the middle of the crossbeam you can see in the photo it has weakened it so I will weld a peace of 13 mm 1/2 inch round bar bent round the gear box to put back the strength . I need to make a rubber engine mount out of some 5/8 thick rubber belting to stop any vibration being transmitted through the crossbeam from the gear box and prop the MK 5 mount would have been to tall [size=150](QUESTION /THE PUMP ON THE OLD EMGINE HAD THREE PIPES TOO AND FROM THE THE TANK ,I THINK ONE WAS A RETURN IT IS SMALLER THAN THE OTHERS AND ONE MUST BE THE FEED BUT THE ONTHER ONE I HAVE NO IDEA CAN ANY ONE HELP) [/size] but Knackered again.

[Luke]

cracking on i see jim

how i did mine was to use the mk5 rubber mount and site the cross beam in the correct position - then make hangers to suit

[JIM T]

The crossbeam on the Hymer is mounted on rubber mounts at the point were it attaches the chasse , not bolted straight to the chasses and a peace of flat rubber placed between the gear box and the crossbeam will give it the same movement as a MK 5 gear box mount . The MK 5 has different engine mounts ,they have a support bracket that touches on the gear box .
On the LDV convoy I have just sold it had the same gear box MT75 but with a Peugeot engine they used a peace of box section bolted from the engine mounts to a point near the clutch cable hole I will make the same support for the Hymer .