A little progress on the gearbox…Due to issues with a batch of faulty parts, the gearbox wasn’t ready for my September holiday. As has been covered in a previous post we managed to get away thanks to a friend lending me a box. Ironically, I received an email stating my gearbox was ready the first day of our three week break. Suffice to say I was not really in any positing to collect until the end of September where it sat in my garage until a couple of days ago.
The box build spec changed from standard to include a 4.14 final drive, stronger 4 pinion differential and new differential bearings. This should compliment my new, more powerful AAZ engine with longer gears throughout and a higher cruising top speed.
Knowing that the gear boxes are prone to corrosion due to its position underneath the camper in front of the engine, my intention was to paint the casings before fitting the box. I thought about etch primer (the yellow stuff that comes out of an aerosol can), but decided to try Hammerite primer on a small section of the alloy to see how well it adhered. After a couple of days I checked and it seemed to have keyed on really well, so the rest of the box was painted.
I am in no great rush to have the box fitted, and the reality is it’s probably going to sit in my garage for the next 6 month until my van is booked in for a service at Brickwerks. I’ll get them to fit it then 🙂 . Hammerite takes a good few weeks to cure, after which I will paint again with a mid grey engine enamel.
I have had a couple of people ask me about the thermal screens I use on my van (seen above on both the window and pop top). Both of these get used on almost every camp over oblivious to the time of year or temperature for reasons explained below.
The pop top roof canvas was purchased directly from Paucer
The obvious reason for buying the screen initially was to try and retain the heat from inside of the van during cold weather. However, we do find that it reduces the noise slightly if camped in busy locations, along with reducing buffeting sounds when windy, and the sound of rain on the canvas. During summer it reduces the amount of light in the van which can be helpful when the sun starts to rise at 5am. After all, who wants to be woken up at the crack of dawn when your on your hols? 🙂
All T3 / T25s have glass window screens and door glass so a thermal wrap is a must if you want to stand any chance of eliminating condensation from the cab area of your van. The Silver Screen was an expensive purchase in comparison to the alternatives that are on offer from the likes of Just Campers etc. At over £100 it was twice as much, but my purchase is still as good today, as the day I brought it. You can definitely see the difference in the thickness of the quilting and the old saying ‘you get what you pay for’ certainly rings true here. The screen cover was brought directly from Silver Screens ( www.silverscreens.co.uk ).
The Atlantic was one of the few vans that came with big mirrors as standard. These were always colour coded from factory in one of three available colours. White, calypso green or red. My van on the other hand came with mat black mirrors.
This didn’t particularly bother me as I always knew I would get round to painting them at some point. It’s just never really been a priority, what with the van getting plenty of use during both winter and summer. However, my current situation means Wolfgang is off the road for the time being, so this became an opportunity….(always need a positive spin with these vans 🌝)
Unfortunately, its not quite as simple as just unscrewing them via the visible screws on the door bracket. They are heated and servo adjustable from a switch module on the left hand, drivers door. This means that the door cards have to come out on both sides. The fallowing video is a guide to removing the door cards for anybody that may need to perform this process: (courtesy of Van-Again on YouTube)
Below is my door after card removal:
Then electrical ‘block’ connector needs disconnecting and stripping….
after which the wires can then be passed through the small cable aperture to mirror.
Its not massively difficult, but a little more involved than one would first imagine.
Then the mirrors need stripping into their basic components before paint. Separating the bracket from the mirror was done using a pair of long nosed pliers . There is large slotted nut (1 in below image) that winds up against a perspex bush (2 in below image) and spring. Again, not the easiest thing to do especially if the nut hasn’t been removed for a number of years.
The mirror glass also needs to be removed. If you look closely in between the glass and the outer casing you can just see the two tabs sticking out on either side. Not particularly clear under instruction exactly how these hold the mirror in, but with a couple of knives carefully slotted down the side, and an up movement on one side, and down on the other, the mirror pulls free of the servo unit.
From the picture above I was slightly surprised to see the original colour inside the casing. I did strip one of the mirrors down even further in the hope that I could just send the plastics and bracket away for spraying, but realized the connectors on the end of the loom wouldn’t go through the hole in the bottom of the mirror. This meant they must have been crimped on after they were thread out of the aperture during construction at the factory. I wasn’t willing to cut them off and re connect after paint, so I left the whole servo assembly in the mirror. You can see more clearly the original paint in the photo below.
I can only assume that the original external paint must have gotten scratched, chipped or dis-couloured to the point where a previous owner decided to take matters into his own hands with a DIY spray-job using a can of mat black paint.
So this was just about as far as I could take it. I was considering getting a few rattle cans made up and having a go at painting them myself. However, these wouldn’t have been cheap, and these on top of the extra wet-n-dry emery paper and primer, would have meant that I probably wouldn’t be saving a great deal against the cost of a professional paint shop. So the paint was purchased and both mirrors and paint were taken to a body shop I had used previously to have my Fiamma Box painted.
Two Days later I collected and I must admit I am pretty happy with the results . I just need to build them up and pop them back on the van 🙂
So my van has gearbox issues! But no reason to stop chipping away at the things that have annoyed me until that can be fixed. Basically, the gaps in my wheels aren’t massive because of the style of alloy, but annoying all the same to see the rusty drum behind. So yesterday / today I jacked the van up, popped the wheel off and set to realizing my goal. To paint the drum red.
Anyways, one thing leads to another, and before you know it (5 hours later actually), I’ve washed away all the mud, painted the trailing arms and stone chipped the wheel arch.
The finished article:
The replacement gearbox should arrive on Tuesday, along with new clutch and slave cylinder from Brickwerks (due to be fitted on Friday locally). Nothing like cutting it fine. We should be on the ferry for our Euro trip just over a week later. Lets hope there are no issues with the replacement box!😳
Sunday 9th April was a gorgeous sunny day that lent itself perfectly to using the van as a base for a family outing at Calke Abbey. Its quite unique in the location we live in as much as the owners (National Trust) allow you to park on the grass fields surrounded by trees and woodlands which forms the long driveway up to the historic house itself.
All in all it turned out to be a very busy day, but in the back of my mind i knew that this would be the last trip in the van with the trusty 1.6TD JX engine that had provided us with so many great journeys since ownership. Getting really sentimental, i guess you could say that we were not the only people to benefit from the trusty power plant, so it makes sense to show its penultimate day in a great light.
So we got back from Calke, and proceeded to rid the van of anything that wasn’t appropriate for the journey the following day. No camping equipment required, but lots of new and refurbished parts in readiness for the trip to the garage in sunny Yorkshire.
Monday we were greeted with another fine day weather-wise, but this was all predicted by the met office so no great surprises, but welcome all the same. We left Derby for Honley just after rush hour and arrived at our destination at 10.30am. The visit to Brickwerks has become an annual pilgrimage. This was our third time and with each visit address increasingly more expensive issues to get Wolfgang back to his former glory.
After a brief conversation with Simon and Micheal, Mandy and I tootled off thinking I was just lacking a fuel pump bracket. This didn’t concern me massively. However, by the time we had walked the short distance to the train station, and got on the train to depart home, emails were telling me the list of missing parts were increasing exponentially. My lack of research, and my over simplification of what could and couldn’t be used from the old JX unit left me in a bit of a sticky situation.
Intermediate shaft pulley.
Intermediate shaft flange.
Intermediate shaft pulley bolt and woodruff key.
Brake vacuum pump.
Oil seal housings for both ends of the crank.
Flywheel end – seal
Timing belt rear cover.
Timing belt upper cover.
Timing belt lower cover.
Oil filter head.
As a recap, I brought a second hand engine from eBay which was similar, but not the same as the engine i needed to put in my van. It was from a later model VW van, and slightly bigger in capacity to the one i had in my van (1900cc) This was an acceptable exchange for the 1.9TD AAZ i needed back from the engine shop. I stripped it back the core engine and sent it away to AW Engineering for checking.
Feedback was positive for the returned unit, and my new engine (AAZ Code) was returned to me at a later date in a polythene bag. This is where it stayed in its packaging until we arrived at Brickwerks.
My van only had four days allocated by Brickwerks to get the old engine out, and new in. If things over ran it would put them in a sticky situation for there future workload. Mandy and I were looking forward to a little shopping and a meal in Sheffield on the way home, but my mind was now on trying to get the missing parts to the garage. With such an early spanner in the works the day had become a little stressful.
With so many parts required i contacted AW Engineering who provided the engine. I knew they were big with VW engine re manufacturing, so they were a good place to start in terms of providing the sheer quantity of parts i needed to keep things on track. Long story short, after numerous emails and phone calls, AW had accumulated a ‘kit’ of parts required to complete the install. £300 was the sum required to purchase bits and have them shipped to Brickwerks.
The following day images of the progression started to arrive via email.
On Wednesday I had notification that the extra parts had arrived from AW, along with this photo to say that ‘It’s in the hole’ 🙂
So that’s where we are at the moment. I’m in a happy place because its really looking fantastic.