Getting the syncro back on the road

[ajdenette]

rust in the eye sucks got that out finally one in 4 pumps is workign so back to the garagein a bit

[ajdenette]

gas in an erritated eye is not a good plan well turns out the was good what i dont have is a good ground but i over pressureised the system and need to do a lot more work on the fuel system and the clutch isnt doing anything at all meaning the pedal is hard as a rock and the arm barely moves with a onkey wrench. so looks like saturday night will be spent going to granby to pck up the westy for the day

[fusername]

if you ever find a good way to pull out the TOB arm, let me know, I still don't have a tool that does it well.

[ajdenette]

I think the engine i just put in will need to come out to get in there it did run on eather and sounded good

[ajdenette]

well added a ground to the fuel pump and she started and idoled though it was hunting and is leaking fuel at some junctions so i need to revisit them and atempt to fix the clutch though it may require pulling the engine or a new bell housing

note to self the fuel filter on the syncro is a real pia to change it mounted to the back side of the shock tower and you need to feel in the dark to remove it

[fusername]

if that tank has been sitting half empty, can I reccomend a fuel cutoff switch from a lawnmower store? Rusty tanks mean lots of fuel filter changes in your future, esp if you run out of gas alot.

[ajdenette]

Syncro gas tanks dont rust no rusting in there EVER platic tanks have some advantages

[ajdenette]

Well to deal with the clutch arm that doesnt move I got a new bellhousing that im going to build up


next i working on etting all new parts from various places hopefully it comes together soon then timeto pull the engine and trans again

[fusername]

new parts, sexy. you order all your seals and junk yet? Also if you need it, and I doubt you do, I have the 091 assembly dvd, pretty pics and all that good stuff for when you forget where washer and stuff go on the parts, but a bellhousing is an easy swap. take some photos tho, I am toying with putting my 091 bellhousing on my 002 so i can throw it in the bay, your trans is going down hill fast, the cold is bringing out the worst in it

oh and we need to play engine and trans doctor soon, Iwanna see a blown 1.9, and i bet you wanna see a locker go into a 091...

[ajdenette]

Well the trick is going to be getting the bushings kits are no longer avalible so its going to be fun

[fusername]

for the cross arm? lovely. Call long and see what they are doing about this. then dig thru mcmaster. I'll help ya if yo uhave dimensions, I am in need myself.

[ajdenette]

well time for an update. i tried replacing the slave cylindar not easy but would give me some clues still not good . My engine and wheels was more wheels than engine as it has pissed coolant all over the garage so it will become a reseal. time to finish the engine in the garage, got my pistons ringed now need to get them to temp the the wrist pins will move. I also discovered one reason why it wasnt running so good before, the rust in the end of the intake runners was aparently adding some unmetered air into the intake . I put the studs into the heads, still wish they didnt say gex that and i picked up a westy top and intirior for the second syncro.


This is my other syncro as i got it


Some cleaning


more cleaning


the new intiror in its previous home


The batted donor.


The interior brought home.


The roof as i brought it home


After i get the silver van driving again synco weekender time

[ajdenette]

lets hope 3 time is the charm...

well the canadian remanufactured engine is rebuilt and almst read to go back in the van now with stock vw cylinders for proper compression, amc heads with new swirl polished si valves and a new bellhousing for the remanufactured transmission whos clutch arem seized and i cant get the bushings to build the brand new one i have



now all I have to do is get the subau transmission in the photo back into my legacy wagon so I can stop driving my mothers forester luckily we have 6 registered cars for the 5 of us.

[ajdenette]

got a bit done yesterday getting the van its getting close to being a runner again.
to deal with the seized clutch arm and the unavailability of bushing i picked up a used 2wd transmission for the bell housing and after some trouble getting the correct gasket it all together.

The day started like this with the van:

The engine had the new rotor, cap, and wires installed and the valves some what adjusted

next i installed the exhaust and bell housing and got the engine from the basement to the garage with some issues i wish i could get some good help once in a while


I knew my rear aluminum panel was cut up never really understood why picked up some syncro parts a while ago glad to put some correct parts back on

and finished sliding the engine under and close to put in still need to get it mated and oil filler on and hung.

I am close but will have to wait for next weekend.

[fusername]

ooh very nice. only diff between 2wd and 4wd bellhousing is the vent holes right? or are they identical? I need to find a new bushing solution soon, my 091 spare is in need, but I may be getting another spare soon...