Roundozo's zed

A little update before my weekend of pain ensues! (and no its nothing kinky!)

At 4pm today I will be leaving work and heading down to visit a mate of mine who happens to live in the middle of nowhere! The reason for this is he has a nice big old barn with a pit and an Aladdin’s cave of tools.

My plan for the weekend is to remove the exhaust (this should be relatively easy as all that’s holding it on are the remnants of one bolt!). Remove the gearbox to replace the clutch and DMF along with the throw-out bearing etc. I will also carry out the CDV delete while down there, flush the box with new oil as well as the diff, replace the prop shaft guibo (I know these used to go “soggy” on the old 3 series). Replace the gearbox mounts, fit new powerflex lollypop bushes, change the engine oil and oil filter, air and cabin filter, fit my ram air scoop and LED sidelights!!! Not much then!!!

As I’m expecting a few difficult bolts I’m bringing along my persuaders. This consists of a hammer, a drill (good drill bits and liquid to keep cool) and my angle grinder! Mwuhahahahah!!

The first challenge however is to work out how to get all of this in the boot of my zed!!!

 
Darkangelv2 said:
Got to love a 'carries anything' ikea bag!

Good luck :evil:
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Yup, currently carrying massive angle grinder, white spirit, pressure bleeding kit and copper slip.
 
Hello all….

Anybody reading through this thread might want an update…………well there is one but it’s not good. I do have pictures of the work undertaken however I’m not yet in a mood to put them up (feeling very deflated)

To sum up……

Gearbox fluid changed
Diff oil changed
Prop shaft guibo replaced
Powerflex lollypop bushes installed
Air filter replaced.
DMF replaced
Clutch replaced

It was all going so well until I tried to get the box back in. It’s just not getting all the way snugly up to the engine. I did use a clutch alignment tool (thanks very much to Machine Monkey for providing me with this, very helpful indeed) however I now feel this might be the culprit. It’s a plastic version and although the clutch looks aligned this is the only thing I can think of that won’t allow the box to go back on. After working on the call all weekend I felt like burning it to the ground by the end of it. How quickly love can turn to hate while working on your car? VERY!

I’ve now given up and really can’t be bothered to continue to fix this myself. I am a keen mechanic however this is one job I will never be doing again. Why BMW insist of using a million different type of bolts is beyond me. The amount of times you need to get a different socket is unbelievable. Even the bleed nipple on the clutch slave cylinder is a peculiar size!

The next stage is………………….I’ve hired a low car transporter and I will be taking the car down to my friendly independent who said he’ll get it sorted for me. I know it’s going to cost but the car is in bits so I’ve done most of the work for him :D
 
Mate i am gutted for you i really am... I do know very well your feelings of frustrations.
And it dose go from love to hate very quickly.

Did you have help installing the gearbox??? We fitted the BMW/Toyota box to the supra yesterday. And it took 2 of us and lots of re aligning and faffing. In the end when we where sure it was aligned we had to use quite a big brass head persuader. to get it close and then brought the gearbox up square and level using the bolts. And we have a 2 post lift witch makes the world of difference. I wont work on cars on axle stands now.

Fingers crossed the garage bill wont be too bad as it will hopefully be quick and simple for them to fit.

Dont be to despondent I was a bit like this fitting my diff.
 
Yeah, had a mate help me, 8hours of giggling and "persuading" and it still won't sit flush. Can't force it in as the ali bolts or worse the magnesium block will get threaded.

At least it'll be nice and ready when I collect.

Think I'll have a break from tinkering for a bit. :(
 
Hello everyone,

After coming to terms with the disaster that was the clutch change, I thought I'd get some pictures up.

This was when work began,


If you want to see how rubbish BMW exhaust bolts are then look no further than the below


After that, got the old clutch and DMF off


Then got the new ones on


Also fitted new powerflex lollipop bushes


Pretty much after all that (including fluid changes) it went wrong. The box just wouldn't go back in and you can't force it because the engine block is magnesium and bolts aluminium.

I therefore have put the whole car on one of these


I have just dropped it off at my trusty Indy so he can put it all back together for me. To help heal my ego after failing I have asked him to also repair the dent in the door so she comes back to me all nice and straight.

Watch this space basically.....
 
You'll get there fella, keep plugging away. Encouragement works best for me in these circumstances so hope it works for you too! :thumbsup:
Stevo
 
Thanks for the words of encouragement.

I have just spoken to my mechanic and the box is back in, wooooo. Now just a few service items and its good to go. Looking forward to getting her back.
 
Roundozo said:
Hello all….

It was all going so well until I tried to get the box back in. It’s just not getting all the way snugly up to the engine. I did use a clutch alignment tool (thanks very much to Machine Monkey for providing me with this, very helpful indeed) however I now feel this might be the culprit. It’s a plastic version and although the clutch looks aligned this is the only thing I can think of that won’t allow the box to go back on.
Click to expand...


Feel your pain, having used one of those in the past, never again! Good idea in theory, but I think the plastic ones just don't hold the driven plate to the cover with enough force to stop that bit of "drop" when you move them from the bench, to a vertical fitting position. I use this type, and swear by them, only a tenner or so on Ebay..

$_57 (9).JPG

Oh God, just realised, I have to put a clutch in my van.. Ah well, it can wait until next weekend!

Mike
 
Good news everyone!

The car is back together, gearbox is smooth as silk (according to my Indy) and she's now at the body shop having the dent in the door fixed. There is also a tiny rust bubble forming on the rear wing near the wheel arch and this is also being addressed. I can't wait to get her back in my arms. :wub: :driving: :thumbsup:
 
Roundozo said:
Good news everyone!
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And there was me hoping for an update on the Dacia Sandero..... :roll:

Excellent stuff dude glad it's all sorted! I hate being parted from my Zed from any period of time!
 
Ed Doe said:
Roundozo said:
Good news everyone!
Click to expand...

And there was me hoping for an update on the Dacia Sandero..... :roll:
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Hehe, I was tempted!

It's not nice being separated, I'm sure she feels the same! I've got some nice roads round my way and driving them in our other car (vw tiguan) doesn't quite do it. I keep thinking the car is broken as there just isn't any power.
 
I spoke to my Indy earlier today and should be getting the car back Tuesday! Wooooo!

He's also done the MOT (seeing Marlon's thread reminded me to update) and she's passed with no advisories. The last thing on the list is alignment and then I get her back. It's only been a week but my God it feels like an age!
 
Loved readingyour thread. Car is looking tops, esp with all the hard work you did. Excellent progress mate, keep up the good work.. working on upgrading your car is like a drug,I won't sell my kids for it, but anything else is fair game, careful you dont get hooked on the same drug. :thumbsup:

Seriously cool thread, mc lovin it ;-)
 
Vanne said:
Loved readingyour thread. Car is looking tops, esp with all the hard work you did. Excellent progress mate, keep up the good work.. working on upgrading your car is like a drug,I won't sell my kids for it, but anything else is fair game, careful you dont get hooked on the same drug. :thumbsup:

Seriously cool thread, mc lovin it ;-)
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Thanks Vanne! Picking her up from the garage tomorrow at 5:45. I'm like a kid at Christmas, I just can't wait to get her back. The alignment has also been tweaked now. Can't wait!!!
 
Darkangelv2 said:
And she's clean! :thumbsup:

How's it driving post clutch and alignment?

PS. Sort your aerial out :P
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Much better! It feels like a different car.

I do want to sort the aerial out but feel I'll let RickRob down if I go stubby. He's such and advocate of the whip!
 
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