Slow and steady wins the race.......

Well done Benny. Seems that you have been a busy man....

Needs more DAZFAB.....lol.....

Cheers

Great work Ben, your excited eh? Hell <big kev voice> " I'm excited" </big kev voice>! Can't wait.

Cheers

ToranaGuy

f**k Gay

Looks great Benj.
Just a quick question, did you include the permant 12v supply on the OBD plug? Alot of the scantools actually power of this.
Foggy

Hi Foggy.

At this stage, no I have not.

The wiring diagrams I have don't include a full description of what the other two wires in the OBD plug are for. I know one is related to the Can Bus so the other could be a 12v connection.

At this stage, I know the PCM gets a couple of permanent 12v supplies, and I will have to test the FEPS line from the PCM to the OBD plug for power when all is turned off.

Cheers
BenJ

Hi Benj,
As per the OBD stanadrd pin 16 is a constant 12v.

Foggy

Clutch Dramas (Again) + Water Pump Dramas (Again) SIGH!!!!!

Clutch Dramas

Soooooo, last week in the rain I was playing somewhat with the throttle, when I realised that instead of loosing traction when the cam came on in 2nd, the clutch was slipping. Hmmmm!

The car drove perfectly fine apart from that so I didn't think too much of it. On Saturday morning I jacked the car up and gave the clutch cable and fork assemble a quick inspection, and all seemed well. I had to go out to run a couple of errands and during that drive, I could feel an odd vibration through the clutch pedal, and the feel of the clutch felt odd.

I had to take my daughter to the airport around midday, and then I visited "That's Gay!" SWC on the way home. All up a good 100km drive. The clutch still had that vibration but it had almost vanished.

I drove to work on Monday, and on the way to and from work, the clutch developed a rather ominous rattle while engaged. I decided to do something about it, and put the wagon up in the air for a thorough inspection.

Once again the clutch fork had dislodged from the pivot point on the drivers side of the bellhousing and as a result was floating left and right as I used the clutch. Arrrrrrggggg!!!!!!

Soooo on Tuesday I pulled the T5 out of the wagon and this is what I found.

Undergoing Surgery


One of the Thrust Bearing locating tabs is completely worn away.


The pivot point is quite worn as well.


The pivot pad on the bellhousing is also worn and the metal wear pad is just as bad.


The pressure plate is not so good either.


My theory is that as the thrust bearing is not applying force centrally on the pressure plate, excess heat is generated, causing some loss of the tension from the springs. This would be part of the reason the clutch was slipping.

Now, luckily for me, I tend to collect bits and pieces as the come my way. I had a spare 2nd hand pressure plate in serviceable condition, a spare thrust bearing and a spare clutch fork. The drive plate looked OK, but I chose to swap it for a spare I had that appeared to have a larger surface area.

I also had picked up another bellhousing, and as the pivot pad area was in near new condition I elected to use this new bellhousing.

I started bolting it all back together, and I had the gearbox ready to slide into the clutch pack and bellhousing when Troyman dropped by to lend a hand. Thanks Mate!

We were lucky and the box slid almost straight home. LP had is foot on the clutch to allow the drive plate to move and it was time to bolt it all back together.

The final verdict is, WOW! A light clutch pedal. My wagon has always had a heavy clutch pedal. Even with two different clutches it had felt the same. Now the clutch pedal feels more responsive and the engagement point is much easier to find and balance.

Back on the road once more.

Water Pump Dramas

After my recent trip to QLD and back, the EL donk was making a bit of an odd noise from the front end. Snap was visiting and we removed the belt to see if the noise would persist.

Without the belt the noise disappeared.

This of course meant something in the front dress was making the noise.

I replaced the idler pulleys on the belt tensioner, followed by the power steering pump, and the noise was still present each time.

I grabbed a long screwdriver and was able to determine the noise was coming from the water pump.

Bugger, I had only replaced it 15 months ago.

I really didn't want to spend another $80 on a new water pump. The BARRA is getting much closer and spending money on an engine I will be removing just seems wrong.

I was browsing eBay a couple of days later, and found a new water pump with pulley for $20 buy it now. Seller was located 15mins away from home, and I new who it was! A few mouse clicks later it was mine.

I installed the new water pump after work one day, and hooray the engine noise was gone.

Hope you are all well and looking after your rides.

Cheers
BenJ

Far out Ben, those clutch drama's must get annoying!

Ford have a solution for the wear in the bell housing, it's a little steel pad that you fit to the bell housing, then you fit your clutch fork & bolt the pivot bolt in as per normal. I had to put one in mine, not the last time I did the clutch (cpl mths ago) but the time before, as my bell housing had excessive wear too. The fork wasn't worn much as I replaced it when I first did the clutch. They are rather expensive new!

I too kept my old clutch setup from the first change, the pressure plate & throw out bearing were rather servicable still, so if I get desperate for a cheap fix, I know I can throw in a new clutch plate for a little while. I don't think that will ever happen tho, I've got a spare (warranty replacement) RPM clutch kit sitting in the spare room lol.

Nice score on the cheap water pump to keep it going for now.

Cheers

ToranaGuy

I did have a plate in there, but it was also very worn. The plate and bolt now in the new bell housing is in much better condition.

The clutch is still going really well, and the wagon is a delight to drive now. The whole thing just feels much lighter and nimble. Funny how the feeling of just the clutch transforms the driving experience. LOL

Cheers
BenJ

"f**k Gay Hey"

are you a meth addict?

No, I am a good mate of Ben's. So pull your head in.

Last edited by SWC on Fri Jun 01, 2012 11:17 pm, edited 1 time in total.

oh ok then. So your really just an unusual old man, fair enough, sorry to interrupt

OOHHHHH I'm Unusual to say the least and many can vouch for that. Your apology accepted.

f**k GAY!!!!!!

BA DOHC 26 - ED Ghia Petrol Tank + OBDII Port re visit

ED Ghia Petrol Tank

In getting ready to test start the Barra I wanted to ensure there was no crap in the ED Ghia petrol tank that could possibly ruin the fuel delivery system, or worst case the engine itself.

So I pulled the tank out of the car, removed the fuel pump, and found it was really clean.



There was only a small amount of fuel in the tank, so I drained what there was.



It was starting to rain, but I managed to get the tank installed back in the car, ready for me to drop in at least 10 litres of 98 ron for testing purposes.

OBDII Port re visit

After receiving some advice from Foggy re the OBDII port specs, I have added in a 12v permanent wire.

Very close now to a test run. It has been raining solidly all day today, so I was not able to put a battery in the car and finalise testing of the looms etc. Hopefully this weekend will be dry.

Cheers
BenJ