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Red Ven

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Re: Red Ven

Postby DG-Unit » Fri Mar 12, 2021 4:44 pm

loot wrote:Will a nice 6 speed with driveshafts from a mk7 fit? :P

Tbh engine and box isn't a problem considering you've done all the work that 99.99% ppl won't touch. I'm happy to weld but really wouldn't have put your efforts in :(

So don't lose heart, get a box fitted.

Only dramas is paying ppl.

I think you should consider changing it yourself. 8)


I have looked at a 6-speed but from what I can tell the ratio of 6th is the same as 5th on a 5-speed so there’s no economy benefit on motorways? I may have just dreamed that after searching a million posts on here. Will defo do the work myself just still not fully convinced it’s the diff. Anyway as it’s a post-2003 I’m hoping Mk7 FWD gearboxes will fit?
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Re: Red Ven

Postby Nordic Blue » Fri Mar 12, 2021 6:25 pm

I don't know how bothered/OCD you would be but you might need to consider getting 6 speed gearstick from a scrapper so it looks the part if you change to that.

I got a spare 5 speed one for mine as I wanted to look into removing the badge in the top and putting LEDs under it to highlight the positions in the dark (just a daft cosmetic thing), but it seems pretty well cemented in there. I didn't want to practice on the actual one in the van in case I wrecked it!

EDIT: I just remembered you're thinking of a MK7 dash conversion so assume you're going with the dash mount stick so won't matter?
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Re: Red Ven

Postby DG-Unit » Fri Mar 12, 2021 6:39 pm

Nordic Blue wrote:EDIT: I just remembered you're thinking of a MK7 dash conversion so assume you're going with the dash mount stick so won't matter?

Yeah defo going for the dash stick so if a Mk7 box fits it’ll save me getting a new gear selector down the line. I’d be up for hunting down a 6-speed if there’s a mpg benefit on an 85ps Mk6 and it fits/ doesn’t mess with the diff ratio. Was going to keep the Mk6 dash but it’s so battered and I need to get behind for sound deadening anyway.
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Re: Red Ven

Postby ned » Fri Mar 12, 2021 6:44 pm

Nordic Blue wrote:I don't know how bothered/OCD you would be but you might need to consider getting 6 speed gearstick from a scrapper so it looks the part if you change to that.

I got a spare 5 speed one for mine as I wanted to look into removing the badge in the top and putting LEDs under it to highlight the positions in the dark (just a daft cosmetic thing), but it seems pretty well cemented in there. I didn't want to practice on the actual one in the van in case I wrecked it!

EDIT: I just remembered you're thinking of a MK7 dash conversion so assume you're going with the dash mount stick so won't matter?


You need a proper gear knob man :wink:
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Re: Red Ven

Postby DG-Unit » Fri Mar 12, 2021 8:05 pm

If my van had a soul and that soul had a face, that would be it.
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Re: Red Ven

Postby Nordic Blue » Sun Mar 14, 2021 4:53 pm

ned wrote:You need a proper gear knob man :wink:


I'm more interested in where you got the cat clutch pedal from!
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Re: Red Ven

Postby DG-Unit » Sun Mar 14, 2021 9:22 pm

DG-Unit wrote:I did take the opportunity to put a bit of sound proofing under the bonnet with a noticeable difference but really need to sound proof behind the dash and that’ll have to wait until the mk7 dash conversion.
E9A4F4C7-1218-4D45-9B3A-F5808411BAA8.jpeg

Bit nerdy but checked it today and the decibel readings in the cab have gone down from 85dBA to 81dBA at 60mph with the bonnet sound deadening being the only thing I've done (as well as removing the factor rust sponges in the pillars).
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Re: Red Ven

Postby DG-Unit » Sun Mar 21, 2021 10:26 pm

Day 209. Finally got down to some serious mechanics and as of this moment I haven’t accidentally broken anything.

Gearbox off. Found the problem. It wasn’t in the gearbox.
4B6DAAF6-D17D-45C2-A3CA-E35BB6880137.jpeg
C06BF6B8-B4E4-41A7-9B7B-25416A54D84E.jpeg
73DB3CC6-CA15-42BE-AC88-3C552C885F15.jpeg
877245A9-836E-412F-BD12-B1413A1CA97C.png


So after being strangely disappointed none of the diff bearings weren’t missing a barrel or scored, I decided to just have a check of the outer CV joints since they were off the van. The near side sounded clunky moving it around while the offside was silent so I pulled off the boots to have a look...
26B93FF9-A967-43E1-993C-3DAD7C297932.jpeg


So might as well still do the clutch and slave cylinder, hoping not a flywheel too. Will also get new driveshafts obviously. Not fully sure on the diff bearings as one of the does actually sound a bit scratchy (nearside) but if anyone can tell me if they look/sound normal in this video I’ll be pleased:

https://youtu.be/VJ2kiBzXiIA

Might also have a go at the power steering pump while the gearbox is out of the way. If I do that then the whole MOT list is complete.
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Re: Red Ven

Postby dumper » Sun Mar 21, 2021 11:30 pm

Not sure if any help we used to get a lot of diff bearings going in mk3 escort vans the first signs of a problem was a weep on the seals and a bit of lift in the drive shaft eventually the speedo drive gear would strip its teeth when you stripped the box the bearings didn’t look bad the preload on the bearings was set by 3 cone washers that acted like a big spring to take up the play they all seamed to go at about 65000miles used just put new bearings in them .
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Re: Red Ven

Postby ned » Sun Mar 21, 2021 11:45 pm

That cv is proper fubar, no wonder if was clunking and banging, I'm surprised it's not seized up.
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Re: Red Ven

Postby DG-Unit » Mon Mar 22, 2021 9:19 am

dumper wrote:Not sure if any help we used to get a lot of diff bearings going in mk3 escort vans the first signs of a problem was a weep on the seals and a bit of lift in the drive shaft eventually the speedo drive gear would strip its teeth when you stripped the box the bearings didn’t look bad the preload on the bearings was set by 3 cone washers that acted like a big spring to take up the play they all seamed to go at about 65000miles used just put new bearings in them .


I suppose it’s possible that play on the bearing has damaged the deal from the inside rather than the usual nicking it with the driveshaf? I don’t like the sound of the scratchy nearside bearing so maybe they need to be done. Want to avoid doing the bearing races if possible and paranoid i’m going to muck it all up and have to have the box off again in a few thousand miles.
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Re: Red Ven

Postby DG-Unit » Mon Mar 22, 2021 9:23 am

ned wrote:That cv is proper fubar, no wonder if was clunking and banging, I'm surprised it's not seized up.


Yep. It has been managing alright for the few very short journeys i’ve done and seems to get better with more movement. That might explain why it seemed to happen suddenly after standing still for 2 months if the moisture in the little grease that’s left was able to eat away at the surfaces without any movement to scrape it off.
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Re: Red Ven

Postby DG-Unit » Mon Mar 22, 2021 2:21 pm

Clutch is out. Looks like it’s got a fair bit of life left in it but another is on the way.
1B9B7814-A996-426F-91AC-88153E2CDC2F.jpeg


Wondering where all the oily gunk came from just behind the flywheel at the bottom
866F31F4-C471-46FA-93A9-EDEE509CDB44.jpeg
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Re: Red Ven

Postby DG-Unit » Mon Mar 22, 2021 4:36 pm

Getting deeper into it now. Flywheel off and clear the rear crank seal needs replacing:

0493184F-FCEF-4E70-B5B2-09F12CF1B5DB.jpeg
285B3B6B-94DB-4677-BBBD-8B14ABC1BDB6.jpeg

Was about to panic when I saw that leak thinking the engine would be on borrowed time but thankfully it’s a simple job with everything else off. New Ford one ordered from eBay and some flywheel bolts.

Then I discover this while i’m cleaning the dirt off the flywheel:
D16596E0-8A77-472A-BC9F-0396CDC1B8B5.jpeg

Not as worn on the other side. No real issues or vibrations and i’ve seen worse. No starter problems either apart from in winter it’s a little shy. Do I need a new flywheel while I’m down here or leave it be? Another argument for changing it is all the oil that’s been all over it from the leak but that should clean up.

Giving the surfaces a clean up being especially careful not to spray or splash anything into the block:
3577B3CC-2F2F-4EC0-8C84-0767B1A93C44.jpeg


Did find more of the mysterious broken rubber seal though:
62BAACFF-7741-4F07-ADC4-683267AF6D1C.jpeg
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Re: Red Ven

Postby DG-Unit » Sun Mar 28, 2021 10:05 am

Day 215 brought me:
Gearbox back together, caked oil in and outside the bell housing cleaned, new driveshaft oil seals, new concentric slave, new rear main seal, new flywheel and bolts, a bunch of dremel wire brush splinters in my arms and face and the panic of deciding to pin myself to the ground under the van with a gearbox for an hour.

Looks like someone has done the clutch and slave before and didn’t put any sealant on the back of the slave so the gearbox was likely leaking from that and one of the driveshaft seals. Amazing it wasn’t completely messed up inside. Was a good idea to get a new flywheel (as long as the new one doesn’t vibrate; £50 felt too cheap but let’s see, it’s all I could find) and clutch even though it wasn’t worn the oil contamination was beyond cleaning. Looks like that rear main seal had been ignored for a long time but the only thing the previous owner did seem to get right was topping up the engine oil.

Day 216 will be:
Achy arms from day 215, removing wire splinters from my work clothes, put together everything around the gearbox, fit new driveshafts, bleed clutch, fill gearbox oil, top up engine oil, new thermostat housing, replace coolant (again), drill drain holes in door steps, rear parking sensors and a mental breakdown if anything doesn’t work and I have to take it all off again. Might watch the motorsports at 3pm.
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