Proper mk7 4x4. (none of yr namby pamby AWD nonsense)

[Punto443]

I’m more impressed that those two pairs of steps can hud up that whole van!!

[Airthies]

Run into a bit of a bollox moment!
I have a starter to flywheel issue
Was hoping to fit the flywheel that came with the gearbox but it's larger diameter than the original so thought the starter with the stand off mounts would work but it's still too close to the flywheel.
Either got to find the right one or space out (bodge) the starter to the correct distance not holding out much hope for getting it sorted tomorrow
Anyone got any suggestions?
I'm kinda thinking it's too much of a miss match as it's the old 2.4 with a new 2.2/3.2 gearbox and reckon the box bellhousing and block backplane are diferent sizes despite the bolt centres all working out ok.
Any ideas folks?


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[Airthies]

I’m more impressed that those two pairs of steps can hud up that whole van!!

I took lots of crap out it to lighten the load so it's just slightly under the 3.5t now

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[Airthies]

Other than that it's coming on nicely, finished the gear cable bracket, and yes !!! (Dancer!!!) I can get in all the gears
and got the shortened prop back and it fits too
Next biggest jobbie is squishing the tank so it fits

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[loot]

What's wrong with the flywheel? The starter gear shots out when you spin it up and it looks OK from here?

[twin--turbo]

the pinion is not far enough out, so it will just hit the side of the ring gear and not mesh.

TT

[Airthies]

Too close to the centre.
Just looking at the two side by side.
They both have the same pinion to mount face hight it's just the nose cone that's stepped back rather than the mounts stepped forward if that makes sense?

The flywheel ring gear is (by my rough measuring) 7.5mm larger in radius than the old one.


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[bambi mk 1]

Is the pick up piont for the crank sensor in the correct position plus have you enough room in the slot for it to clear the flywheel The euro 4 and euro 5 flywheel wont interchange PS is the teeth pitch the same

[loot]

OK so a couple of washers fitted over the dowels for the starter then? If it is just the diameter of the ring gear, few mm? You could also make an aluminium or other material plate as a gasket.

As long as the starter pinion has the right throw and teeth etc then it seems like a small problem to me, you could make longer dowels and a gasket which just holds it the correct distance from the ring gear, as long as it is secure.

[Airthies]

Is the pick up piont for the crank sensor in the correct position plus have you enough room in the slot for it to clear the flywheel The euro 4 and euro 5 flywheel wont interchange PS is the teeth pitch the same

Having more closely measured the flywheels the stator rings are the same other than a narrower tooth face 3.5mm on new one compared to 5mm on original.
The mount face to stator offset is 1mm different 16.5 for new one 15.5 for old one which takes it closer to engine but then ring gear is also stepped further from engine so space should be ok

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[Airthies]

OK so a couple of washers fitted over the dowels for the starter then? If it is just the diameter of the ring gear, few mm? You could also make an aluminium or other material plate as a gasket.

As long as the starter pinion has the right throw and teeth etc then it seems like a small problem to me, you could make longer dowels and a gasket which just holds it the correct distance from the ring gear, as long as it is secure.

That is one of my options/plans
An I've got heavy foam strips we use on machines which will fill the gaps

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[ned]

Can you not swap the sprockets from one starter to the other? One looks smaller on the picture.

[Airthies]

Can you not swap the sprockets from one starter to the other? One looks smaller on the picture.

No one question I asked the guy from the starter motor tech support yesterday was are there diferent tooth count between options an he said no...
Also considered swapping ring gears but that's not a goer either.

Yep so plan is...
Shim out starter, I've got spare longer dowel pins (as new gbox came with some in the mounting holes) so it should be held in the right place.
Then fit flywheel and check pinion throw and sensor pickup clearance then try starting an see if Ican get a tune out of it with that setup, if it doesn't then the old flywheel and serviceable clutch are going back in till I get it on the road and get a new one


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[Airthies]

Is it missing the flywheel, but just very close to it? It's just it looks like the starter motor meshes perfectly with the ring gear.

What's the Ranger starter motor like, have you been able to try one?

I priced up a ranger starter but it was coming in at near £400 due to no exchange unit and next day carriage and non returnable if wrong, so wasn't keen to "take a punt" on that one not seen an old one and can't find pics either. Don't think ranger owners are quite as

Will you're original flywheel and starter not fit with the new g/box?

The original starter won't fit due to the larger bell housing of the gearbox but the new one would fit with the old flywheel.

Otherwise maybe cut a spacer from aluminium?

Use what you got steel shims and longer dowels fresh off the vice

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[Airthies]

Can you not swap the sprockets from one starter to the other? One looks smaller on the picture.

No it's just further into the nose cone

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