2.1 vw microbus gearbox


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Rover SD1 2300cc, 2600cc Clutch Failure Due to Gearbox Misalignment

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Filed Under (Rover) by admin on 05-06-2011

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Symptoms of clutch drag, and/or notchy release operation, can occur within 500 miles of replacing the clutch, when the gearbox is replaced misaligned to the engine. This is due to the release bearing operating off-centre to the clutch cover diaphragm spring, causing excessive fretting between the two components. Premature wear to the fulcrum ring of the clutch cover, causing clutch drag, broken driven plate centre, and wear to the spigot bearing in the flywheel, can also result. A special dowel bolt, which is an interference fit, is fitted to the lower left hand position of the gearbox bell housing, (see diagram). This dowel bolt is frequently incorrectly replaced with a normal threaded bolt, for ease of fitment of the gearbox. Above the starter motor position is fitted a dowel pin, (see diagram). This is sometimes pushed forward when fitting the gearbox to the engine, and protrudes out of the front face of the engine adaptor plate, instead of being flush. In this position the dowel pin will not locate correctly with the gearbox bell housing. The dowels must be located before the remainder of the gearbox bell housing to engine adaptor plate bolts are fitted and tightened up. Should either or both dowels be missing, or not located correctly, misalignment of the gearbox will take place.

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2002 Land Rover Freelander Automatic Transmission/Transaxle: Service and Repair Gearbox -KV6 -NAS Models

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Filed Under (Rover) by admin on 07-05-2011

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JATCO Gearbox – KV6 – NAS models Remove 1. 2. 3. 4. Position the vehicle on a twin-post lift. Tie bonnet back in upright position. Disconnect battery earth lead. Remove engine acoustic cover. 5. 6. 7. 8. Release HO2S multiplug from support bracket on LH camshaft cover, disconnect multiplug. Raise vehicle on lift. Remove rear beam. Remove RH catalytic converter. 9. Remove 2 nuts securing front pipe to manifold. 10. Release and disconnect post catalyst HO2S multiplug. 11. Release post catalyst HO2S harness from clips. 12. Remove bolt securing front pipe to bracket and remove front pipe. Discard gasket. 13. Remove 3 screws securing LH splash shield and remove shield. 14. Release HO2S lead from clip on cylinder block. Remove 4 nuts securing exhaust manifold to cylinder head, remove manifold and discard gasket. 15. Drain fluid from IRD. 16. Drain gearbox fluid. 17. FitLRT-54-026 to the RH drive shaft inboard joint. 18. Using a suitable lever, release drive shaft from IRD. 19. With assistance, pull hub outwards and release drive shaft from IRD. CAUTION: Care must be taken not to damage oil seal when removing drive shaft from IRD. CAUTION: To avoid damage to gaiter or joint, do not allow shaft to hang on joint. 20. Remove LRT-54-026 from RH drive shaft inboard joint. 21. Remove and discard drive shaft circlip. 22. Remove bolt securing lower engine steady to sump mounting bracket. 23. Remove lower engine steady noting that ‘TOP’ mark on engine steady faces uppermost. 24. Reference mark front propeller shaft for reassembly. 25. Remove 6 nuts and bolts securing propeller shaft to IRD drive flange. 26. Release propeller shaft from IRD drive flange and tie shaft aside. CAUTION: Care must be taken to support the Tripode joint when removed from the IRD unit. To avoid damage to gaiter or steel can, the joint should not be allowed to fully extend or be dropped. 27. Disconnect breather hose from IRD housing. 28. Position container to collect coolant spillage.

Retro fit of the Audi Auto dimming rear view mirror

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Filed Under (Audi) by admin on 16-06-2010

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recommend you disconnect the battery first, and make sure you ground yourself to the vehicle chassis, as you will be working very close to the Airbag system. 1. First of all remove the centre light surround. 2. Remove the three screws that hold the main body in place, one is behind the sun glasses holder. 3. Remove the main body of the internal light console. And disconnect the main plug, as we will need to fit one of the connections on 4. This the tricky bit, remove the “A” Pillar interior trim. The trick is to get your fingers behind the very top of the trim, once you have two fingers behind the trim, pull quite hard until you see the top clip pop out. There are three in total, don’t be scared to give it some force, as the clips will give. Now you have this piece of trim out, remove the small piece of trim down by the door hinges, along with the fuse cover. The Gearbox wire can to be connected to the following depending if you have an auto of manual transmission. Manual gearbox: 32-pole Gray connector (vehicle on-board control system) by soldering to PIN 9 (backwards signal) Automatic gearbox: Beige connector (central control device comfort system) PIN 8 The location differs depending on what model you have. However I did not connect this wire, as I could not find the unit. But I believe it’s behind the steering wheel. 8. The best fuse block to use for connecting the 12 volt ignition is the Brown fuse connector

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2002 Jaguar X-Type A/T – Difficulty Selecting Range

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Filed Under (Jaguar) by admin on 21-09-2010

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Difficulty Selecting Transmission Ranges – GEARBOX FAULT Message – Reset J-Gate Remove and destroy Bulletin XT307-01, dated 08/01. Replace with this Bulletin. The adjustment procedure has been revised. Issue: Some 2002 MY X-TYPE vehicles with automatic transmissions may experience customer complaints of being unable to select a transmission range, or the message ‘GEARBOX FAULT’ flashing on the message center (or the powertrain malfunction lamp [MIL] illuminating) causing the vehicle to run in limp-home mode. Action: Using WDS, check for any diagnostic trouble codes (DTCs) stored. If any DTC is stored (see table), the J-gate assembly is functioning incorrectly and needs resetting. In order to do this, follow the Workshop Procedure outlined below. Note: Before starting the J-gate setting procedure, ensure the vehicle is cold, or has been left to cool for at least 2 hours.

2005 Honda CR-V – Maintenance Schedule for Severe Conditions

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Filed Under (Honda) by admin on 09-01-2011

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Service at the indicated distance or time, whichever comes first. Use this schedule if the vehicle is driven MAINLY in Canada or in any of the following conditions. If only OCCASIONALLY driven in these conditions, use the Normal Conditions schedule. Severe Driving Conditions Driving less than 5 miles (8 km) per trip or, in freezing temperatures, driving less than 10 miles (16 km) per trip. Driving in extremely hot (over 90 ºF/32 ºC) conditions. Extensive idling or long periods of stop-and-go driving, such as a taxi or a commercial delivery vehicle. Trailer towing, driving with a car-top carrier, or driving in mountainous conditions. Driving on muddy, dusty, or de-iced roads. Do the items in parts A, B, C, D, E, F, G, H, I, J, and K as required for the mileage/time interval listed. NOTE: According to state and federal regulations, failure to do the maintenance items marked with an asterisk (*) will not void the customer’s emissions warranties. However, Honda recommends that all maintenance services be done at the recommended intervals to ensure long-term reliability. Replace engine oil every 5,000 miles (8,000 km) or 6 months. Engine oil capacity without oil filter: 4.0 L (4.2 US qt). Replace engine oil filter every 10,000 miles (16,000 km) or 1 year. Engine oil capacity with oil filter: 4.2 L (4.4 US qt). Check front and rear brakes every 10,000 miles (16,000 km) or 1 year. Check pads and discs for wear (thickness), damage, and cracks. Check calipers for damage, leak, and tightness of mount bolts. Lubricate all hinges, locks, and latches every 10,000 miles (16,000 km) or 1 year. Rotate tires, and check tire inflation and condition every 10,000 miles (16,000 km). Follow the pattern shown in the Owner’s Manual. Inspect tie-rod ends, steering gearbox, and gearbox boots every 10,000 miles (16,000 km) or 1 year. Check rack grease and steering linkage. Check boots for damage or leaking grease. Check fluid lines for damage or leaks. Inspect suspension components every 10,000 miles (16,000 km) or 1 year. Check bolts for tightness. Check condition of ball joint boots for deterioration and damage.