Thanks guys! Today was a very satisfying dash tidying up day.
* Fixed the dash clock - the old one was cracked.
* Replaced the heater controls - old one had broken mounting tabs
Now I can enjoy the luxury of turning off the heat during the summer!
* Retrofitted the headlight switch backlight with an LED.
Also installed my replacement oil dipstick funnel.....broke the original one while messing with the AC compressor a while back.
Edited since I forgot to include a bunch of other work on the car.
Valve cover gasket replacement and cover painting
I was wondering why 7 of the nuts were easy to remove and the 8th required an allen key own: to remove. Then it occurred to me why the valve cover wasn't quite sitting right on the head:
I stopped by a couple of places today to get the replacement valve cover stud - no one had the shouldered stud and I was even GIVEN a straight one by one place. I'm not feeling to great about 7 shouldered and 1 non-shouldered stud. :-k
This evening I finished degreasing the valve cover and CHEAPED out on paint - you can't imagine how many $6.99 rattle cans I have used for various projects in the last 6 months.
So I grabbed a can of white enamel left from painting my youngest daughter's bed - one of the few "decorating" projects that did not necessitate Pottery Barn colors.
Boy if anything is leaking, I sure will see it in a hurry. [-o<
After I put the valve cover back on, I forgot to put the windage tray back in after tightening all 8 nuts!
And then on top of that, the tiny rubber grommet at the tip of the accelerator cable crumbled in my hands.
But, finally, it is all back together. I cleaned up the intake manifold and wiped down a lot of grease from the hoses/tubing. That white valve cover does not stand a chance - but it will be fun to look at for a little while.
Ready to drive for the weekend! Yay!
Front struts, an axle and a bunch of other junk
This morning I loaded up the kids to take them to ballet class, started the engine and found my gas pedal lying limply on the floor. The bushing to the accelerator cable disintegrated and the cable no longer stays connected to the pedal. So we didn't get out of the garage.
*clenches fists and drops to knees while gritting teeth together in frustration*
I'm going to rig it up with zip ties and some rubber washers to hobble through the rest of the weekend.
Placed an order for the replacement bushing one on http://4crawler.com/Diesel/ForSale/AccelPedalBushing.shtml.
Bummer - no Cabby action today. :x
Got a wild hair and took of the left side drive axle since the CV boots were puking grease all over the place. And it was starting to get a little noisier as grit entered the boot. Things went well....nothing stripped, broken or screwed up.
I got my high-tech throttle pedal bushing in the mail. ┬ But I am satisfied with the ziptie for the moment but will change it shortly. ┬ I will probably also buy some shift bushing parts from the same guy since my shift rod bearing crapped out.
First priority is working on that new axle I took out yesterday.......So I got a new strut mount and changed that. ┬ That could have gone smoother, but successful nonethless. ┬ Strut is okay for now. ┬ I will totally need alignment since I completely lost track of where the eccentric bolt was set. ┬ I still need to change the other strut mount as well.....should go easier since I have a feel for everything (and don't need to mess with the axle on that side).
Sorry to disappoint, but I flaked and decided not to change the diff seal. :? ┬ ┬ Just cleaned everything up to prep for the new axle.
The axle was a bit of a headache because I had to pack the grease for the inner CV - YUCK. ┬ That grease sucks. ┬ I got it EVERYWHERE. ┬ I got everything bolted together, but not everything torqued just yet. ┬ I want to put the car back on the ground before muscling everything - especially that axle nut (177ft-lbs). ┬ I'll do that tomorrow....too tired now.
I took the axle core back to the store today. ┬ The parts guy gave me a roughing up about returning a core [*******]8 months[/size] after buying the rebuilt one. ┬ But I got my $60 core credit on a gift card......and you can bet I will be using it for SOMETHING later.
Today was simple, but I wanted to take my time on torqueing everything methodically so I wouldn't miss anything.
I also cleaned up the axle grease that spun onto the fender well.
I found that in my rabid camera shots of the projects that I had a great reference photo for the eccentric alignment bolt position before I took it apart. ┬ Lined it up back to that position and was all set. ┬ This assumes the original alignment was worth a damn. :x ┬ This buys me a little time to work up to changing the other front strut mount later on.
Before and after shots:
With the driver's side strut mount replaced, I took on the passenger side. I had the assembly out of the car in 15 minutes. Compressing the spring takes the longest time without air tools. But when I took the assembly out, I found the strut insert was leaking. Bah! Need a new strut insert! Which means I have to replace the other side too. Shucks.....and right after I had just but that side back together. own:
I didn't have a pipe wrench big enough to take the cap off the strut insert. But channel locks and the jack bar worked.
This is how bad the passenger side mount was: [Click here to watch VW-Mk1-Front-Strut-Bearing-Worn]Click here to watch.
Put it all back together and set down the passenger side. Repeated for the driver side. I hate doing things over - but I have to say it is good practice and I get it done faster now. :::
And I'm standing there looking and the engine bay and realize that the passenger side mount is missing the washer on top of the mount nut. WTF?! :cussing: Awww man......I had put the washer UNDER the mount for some boneheaded reason. ](*,) That's what I get for rushing. So this afternoon I have to take that apart AGAIN and assemble it correctly.
That means I will have removed and installed BOTH sides TWICE. #-o
Modified by JPX at 1:48 PM 5-5-2007
Modified by JPX at 8:14 PM 1-30-2008