Cosworth 2.9litre in my Crewwy

[dickspanner]

I am not sure if this would be contraviening copyright laws or something but has anybody got an extract of how the brake servo works and the pipework etc so I can plan how I am going to feed it etc from this cosworth engine. I think at present the solid pipe ends just where the driveshafts go so I am possibly missing my one way valve.

I do have a haynes comic (not with me) and the electronic version etc but just nothing with me a present and wanted a read over lunch.

Cheers

Dickspanner

[toomanytoys]

Yeah, need the one way valve and connect to the engine side on the inlet manifold (engine side of throttle body) to get max vacuum..

Personally I dont think over riding the fan is the correct method.. if the engine is getting hot and the rad isnt really (fan switch should operate when the rad sees 95 or whatever it is, this means the engine will be a bit warmer...) the water isnt circulating properly... if the rad is getting hot then the switch could be at fault... so running the fan manually would work..

What stat is in it? does it have a temperature stamped on it... is it a gen ford one or a cheap aftermarket? what temp do they run at in the cossie..?? some engines are designed to run hotter to improve efficiency..

[dickspanner]

To be honest Si I have parked the water side up for the moment and the pump is just sat on my cargo bed waiting to be installed. I will investigate further later.

The big issue at the moment is the gearbox. After the extra large can of whoopass was opened on my motivation with the gearbox issue this is all that is playing on my mind at present. Due to the economic downturn and pay cut I recieved I have had to cut living costs and one of the cost saving that was made was my monthly subscription to 'Rent-A-Pal' so I have just spent another three hours on my own at my lock up trying to undertake a what I would realistically call a two man job trying to sort the selector problem out. In out In out, under over under over, it was like the script from a porno I was in and out of my cab so much and climbing all over it trying to line up the selectors on the gearbox. Remembering that not only have I had to build a 4 speed selector box housing I have had to modify the onion holder bracket. But after another couple of skin sizzling welding sessions, clamping swearing banging head etc, I though I had completed the task. From underneath the shaft seamed to be hitting all 5 gears (4 forward and one backwards) From in the cab it felt like I had achieved the goal.

The crewcab was put back down on floor and fired up. 1 fine, 2 fine, 3 fine, 4 fine, reverse a real big f*(kin NO. Well what and how do I describe it. It goes into reverse. How can I best describe what is happening. It is like the crewcab is parked on a hill and all the brakes are on and I am trying to reverse up it. Apply revs, slip the clutch and it stalls the engine. What the blithering heck is wrong with this thing. I seriously spat my dummy, threw a couple of tools around, kicked a few things, packed up and f*(ked off. I am so pi55ed off with this thing now, it is the only thing that is holding me up from getting the thing MOTed. Where do I go from here. I have two VW what I call experts next to me but I know they will not be able to resolve this issue, it is too far from standerd from them. I need help but at this moment in time I just don't know where to turn. Is there a fault with the gearbox. Are the selectors not doing what they should, I just don't know. This has really just stopped the thing at the last hurdle. I really do not want to pull the whole assembly out again as I have had it up to here with it all.

On a lighter note my wee man has started doing the actions to big fish little fish by bob the builder which is cool.

Dickspanner

[dickspanner]

As promised a few piccies. Sorry about quality these were taken with my I-Poo phone.



Current practically finished crewcab.



Current practically finished crewcab.



Rear of fan with connections previously mentioned.



4 and 5 speed selctor comparision.



4 speed selector modified.



4 speed selctor fitted. Appears to sit well in the cab with pivot point just below hole and no strike through entire movement with bodywork. Well chuffed.



Test rig of rad fitted from a T4 running on cosworth engine. Test proved to be OK. Had to blow cool air through rad as did not want to waste time wiring the T4 cooling fans up.



Inline Jag water pump



Additional dials fitted to dashboard.

Really feel like getting a branch and giving the thing a dam good thrashing at the moment. I like a challenge and will overcome many things but this gearbox thing made me want to push it out into the yard and set fire to the thing dancing round it naked with a dandilion in between my butt cheeks chanting to the moon God.

Hey hoe onwards and upwards.

Dickspanner

[windysurfer]

Keep at it Dick. It'll be worth all your hard work when its finished

[toomanytoys]

Ah I see why it wasnt a straight swap... the van was originally TD wasnt it?? Higher floo rin the gearstick area... just adds to the confusion and stress...

Now I cant promise this... but I may... just may... be in the area some time next week..... I hope ...... more than willing to give you a hand.....

[dickspanner]

Well tonight has been a different story. A fresh mind and a fresh attitude to it all.

I stripped the gear linkage down that I had done and manually engauged reverse and tried it. Reverse worked so I breathed a massive sign of release realising the gearbox was not at fault. I tested the linkage lever and found there to be alot of play in it so it had to be replaced. The lads from round the corner had a new lever on the shelf so it was replaced. No more play.

With the new lever fitted and all play removed, and keeping all the work in place which I did last night I collared the lads and got them to help me in the re-adjustment. It was adjusted up the best we could and tried it, at last a reverse gear. Jees I am a happy bunny. All 5 gears now work. The selection is a bit baggy and I think I am going to have to make a manual selection gate to fix into the 4 speed selector box that I have modified to try and tighten it all up as the gears are a bit floaty.

Two remaining jobs to do over the weekend and it is now booked in for a MOT on Monday.

I have these little jobs to go like plumb the servo in and install a couple of exhaust mounts but after that.. Fingers crossed it should be fully legal on Tuesday.

I will keep the thread updates as the weekend goes on.

Dickspanner

[dickspanner]

Si,

If you are in the area, you are more than welcome to pop in and I will make you a brew and you can see the progress so far. Last night was a bit of a rant as I had lost my rag charley big time.

I will at this point in the thread give a big heads up to Toomanytoys and Aiden ' The Man' Talbot for all the earache I have given them over the phone over the last week and at no point have they refused to give very usefull advice and help.

CHEERS FELLAS YOU HAVE REALLY HELPED ME KEEP MY SANITY.

What these two guys do not know about T25s is really not worth knowing.

Dickspanner

[dickspanner]

Oh and one last thing, it goes like stink

Not that I have even put full power through the box, I am sure it will light up the tyres in every gear when I can eventually hit the loud pedal and dump the clutch.

Enter 'The Man' Talbot to allow me that pleasure eventually.

[jamesc76]

Glad its coming together buddy!!!!

[dickspanner]

Cheers James.

It has been a baptism of fire but this forum and the knowledge of the guys on here has made it possible to get to this stage in the project.

Once MOT'd the next stage is bling.

This thread will stay live as there are still lots of mods to make to it in relation to the mechanics of it all.

I have just been looking on ebay and there is a selector repair kit, has anybody fitted one of these and did it tighten up a baggy gear change? It is £50 from B&B and don't want to waste money if I can tighten it up myself for a fraction of the cost. But at this moment in time gear selection is shall we say a bit erratic to say the least. I can put some of this down to all the modifications that I have made to the selector box and the onion holder but I feel that the actual pivot point of the selector shaft has excessive play in it.

Once MOT'd I think I will have to modify the brakes but do not want to commit to this untill I have the servo fully up and working and get a true feeling for it all.

The exhaust is going to be fully rebuilt but I must comment on the fact that it is very quite on tick over and increases in volume when the loud pedal is pressed. Which is nice. Coolant is still an issue, wiring is still an isse, no alarm, no stereo, no rear seats, no load deck, cargo box needs attentionetc. The list grows the more I think about it.

Dickspanner

[toomanytoys]

Si,

If you are in the area, you are more than welcome to pop in and I will make you a brew and you can see the progress so far. Last night was a bit of a rant as I had lost my rag charley big time.

I will at this point in the thread give a big heads up to Toomanytoys and Aiden ' The Man' Talbot for all the earache I have given them over the phone over the last week and at no point have they refused to give very usefull advice and help.

CHEERS FELLAS YOU HAVE REALLY HELPED ME KEEP MY SANITY.

What these two guys do not know about T25s is really not worth knowing.

Dickspanner

Thanks.... no problem mate... here to help if I/we can... love to be closer so as to have been able to give you some hands on help..... with the truck...

Know of any spare rooms within reasonable distance of UMIST??? (pref sharing with a 24 yearold swedish blonde nympho.... pref female!!!!

[dickspanner]

Glad you put femail at the end fella.

Found a nice place to get some ally plate from for my load bed, just got to raise some jingle for it now.

Dickspanner

[Aidan]

er which gearstick are we running and front linkage ? if five speed and it's driveable leave it till you decide on final box to use in case you decide to go 5 speed
there should be a mm or two of vertical play in the stick before the detent spring, more than that and a rebuild might be required but may be just due to total loss of lube not unknown, Baxter sells them may be best source -genuine vw from Simon. Other sloppiness may be due to worn onions, front one behind fuel tank never gets replaced or lubed and rear one can be well worn as can shaft, and depends on type, early same as front or late with the extra boots. £20 kit on ebay gives you new selector arm/ball and one each onions. Aftermarket but genuine nla except for arm /ball which is nearly £30 inc vat from VW. Also cup on rear linkage can be quite worn.
When fitting ensure cupa and ball well mated and skirt of boot pulled down over cup before locking of the two m8s holding the onion plate on the gearbox case.

Glad it was linkages though

[dickspanner]

I was thinking of this kit for the front end.

http://cgi.ebay.co.uk/VW-CAMPER-T25-TRA ... 7C294%3A50" onclick="window.open(this.href);return false;

And I have already replaced the ball part of this kit

http://cgi.ebay.co.uk/VW-CAMPER-T25-TRA ... 7C294%3A50" onclick="window.open(this.href);return false;

I am running a bit of a hybrid. I have a 4 speed selector assembly framed down so the rod is in the same line as the original 5 speed. I then have a 4 speed front rod and a five speed rear rod. I had to extensively modify the onion carrier as the cup was not socketing into ball. All the gears can now be hit and it drives fine. The main problem is it is very easy when going for Gate 1/2 to go a bit too far and hit the reverse gate. the movement of the stick is far to excessive when looking for either 1/2 or 3/4 and selecting is a bit of an art. Once a gear is selected the stick is acceptably rigid due to the length of movement through the system. I would not accept the amount of movement in say a direct stick to gearbox configeraton but I am happy with the play when in gear.


Nipped to B&Q and got 18mm marine ply for the load deck this morning and gfoing to order some chequer plate this week.

Dickspanner