11/20- Cleaned out and replaced hood insulation with setup from Rob
Budd. It looks cool with the silver decal.
12/5- Hood insulation looks cool, but it's starting to sag in a few
spots. The glue I used was 3M interior spray glue, may have to
pull it and redo it. Hope I haven't ruined it 'cause it was
expensive.
mileage: 204,384
12/09- TB/WP job, John Cho (Tomcat) gracioulsy loaned me his Kempf tool
and I
got started on 12/9 with the 'worldwide tb/wp party' that never really
happened.
12/11 Got into the job and realized I was going to need all
new sprockets, the cam gears and oil pump gear are dished and badly
worn. I've order them to be
sent
overnight from 928 intl. I also ordered the steel crank gear, but
don't know if it needs it, this one isn't aluminum and doesn't look bad
at all.
12/11 Got some much needed help from online
about the tensioner, it's in bad shape and all stuck together so it's
hard to tell how it's supposed to come apart.
12/14/06 Got the new water pump in (remembered the anti-seize)
got the
tensioner in (after futzing with the spring backward). I had to
fabricate a new ground
strap, mine
was broken and had been jumped out.
I also painted the belt covers, which came out pretty cool. I
like the way it looks and I can't wait to see it when it's done.
I got the belt on, but when I went to turn it, its' off by exactly 1
tooth on both cam gears. They're both really consistent though
(through several rotations)
so I think I've got the technique
down.
I took some notes as far as differences between the '85 and John
Pirtle's write-up for the '87. I'll put these on the site
somewhere.
12/15/06 Cranked up the car, but there's a bad chirp chirp
sound. Shut it down and check it out.
Found that it was the bolt for the tensioner
roller, I put it in backward, need to take everything out to get the
center cover off and remove the tensioner
arm . Here's a pic (that groove with no paint
shouldn't be there!).
12/18/06 Got everything back together and turned the key-
YES. Everthing looks good. Ran it up and down the road, no
issues.
Total time for TB/WP, about 20 hours over 1 1/2 weeks. Cost of
parts-
eh, lots.
1/6/07 Forward shift ball cup 'mod' - This didn't start
out as a 'mod' but it turns out I like the really tight shifting.
1/13/07 Rear Seat Delete started- I hadn't planned on starting
this, but when I started to clean out under the rear seats I just
couldn't put them back in, they were nasty. So I started thinking
and trying some things.
2/3/07 Installed Motorsport crossovers with 100cpi cats and new O2
sensor mileage 204,928. Passed inspection!
Also got headlight relay from Andre and headlights go up and
down. Checked/adjusted belt tension, refilled oil in tensioner (a
little leak found) and replaced front brake pads.
2/15/07 replaced rear brake pads (still squeaks. may need to get
rotors cut, or check on parking brake)
Check out Emissions story
205K!
3/31/07 This was a good week, and a bad week. I spent last week
working on the car while the wife was in Ireland.
205,500 miles
Rebuilt PS rack
Rebuilt PS Pump
Replaced tie rods
Replaced sway bar bushings
Fixed leak at
crossover-to-exhaust clamp.
** car was a little low on oil. added 1/2
quart or so and it's right in the middle of the range again.
Car ran like a dream. Silky smooth and really
nice. There is a huge difference. Car was so smooth that I
drove it really aggressively and ended up with a noise coming from the
clutch and it started to shudder a lot when I let out the clutch in
1st. The noise is a very pronounced squealing or squeaking when I
let out the clutch all the way either in or out of gear.
I did some searches and I think it's the pilot bearing for the
clutch.
Now I'm looking for all of the clutch parts
The search I did showed this advice from Jim Bailey:
The minimum clutch service should
probably be ...release bearing , pilot bearing , ball socket for arm ,
friction disc and as was mentioned the updated clutch
release arm and new guide tube. If the pressure plate fingers are worn
from a failing release bearing spinning the race then it needs the
plate. The short clutch drive shaft if
the splines which engage the discs are worn , replace. If the fly wheel
is blued/ grooved , resurface.
Also, there was a recent thread on Rennlist about this service for an
'85 so I read up on this as well. It looks pretty easy to
replace, but I need to scrape together the funds because I just spent
my April allowance on some carpet and other interior stuff because it
was running so good.
4/5/07 -4/21/07 car was off the road!!
mileage 205650
OK, replacing the clutch was a MAJOR hassle that took three
weeks. Getting the old clutch out was the biggest problem.
check it out But eventually with a
lot of advice, I got it out.
Here's the list of parts replaced:
Clutch discs (both)
pressure plate
release bearing (throwout bearing)
pilot bearing
release arm ball bushing (this was gone completely) I think this
caused the noise when the pedal was all the way up, but the friction
disc was worn down to the rivets, and now I don't have to worry about
anything for a while.
clutch slave cylinder (bled out clutch portion of hydraulic system as
well)
Parts that were OK
i-shaft (intermediate shaft)
i-shaft sleeve
intermediate disc or starter ring gear
I also didn't remove the flywheel and have that resurfaced. I
probably should have, but I was pretty deep into this already and
didn't need any more vendors/tasks to complicate it.
Got the car back on the road with new tires on the back (thanks John)
and it runs great. The clutch feels perfect and is nice and
smooth.