Club 80-90 Forums

Hi guys

I tried to remove my dash today and got stuck on one of those damm shear bolts 3 hrs later and it still there! I will get it though...

My plan is to get to the fan and get it running again as per wiki. (wd40 etc)

As it is a total pig of a job, I only ever want to do once. Is there anything else I should/could be looking at whilst the dash is off??

All I can think of so far is to clean up the earth crowns?

No other suggestions?

Hmmm -
Whilst the dash is out I would. ..
1 - clean the earth crowns
2 - check for early signs of rust and treat with Vactan.
3 - because I am a bit ocd, I would tidy up the looms and ensure all connectors are clean and secure.
Generally check and sort everything that is visible...

a nice frash pair of mole grips will undo the shear bolts
you can just grip the bottom small flat part

grips should be good American or uk , not Chinese tho

As it is a total pig of a job

one you have done it its not that bad a job!

wait till you try and undo the heater box! wd-40 the threads from outside (side of radiator) first

Yep, mole grips or vice grips.
Just keep worrying at it!
Spray of WD40, Pluslube etc on threads above may help too.

If the fan is totally shot, the old fan can be removed without disconnecting the heater hoses - if you can get the plastic case separated. See Wiki article about the 11 clips.
Contrary to some models, mine had no screws from through the top grille, all 4 from inside plus 2 brackets onto the crossmember. Take the brackets off comletely, 2 nuts each.
A long phillips screwdriver is needed for the two on the steering column side and take off a hard plastic piece of s-shaped ducting that goes behind the brake servo.

pi quattro wrote: My plan is to get to the fan and get it running again as per wiki. (wd40 etc)... I only ever want to do once

If you only want to do it once, change the flippin motor WD40 won't fix 30 year old knackered bearings and the motors are only about £35 from Brickwerks.

Well I got the damm bolt out!
I tried all sorts of mole grips pliers, hammering old sockets onto it, in the end I took a drill to it and drilled through the bolt!

On to the next step....
Having a think about a new motor & fan but I hope that wd40 and a spot of oil might work.

Or manufacturing some sort of tube that I can pour oil down to lubricate the bearing? Lol

you will need to check the bearings closely

the brass bush ( bearing) seizes on the shaft . this then rotates with the armature . can be difficult to unseize

I'll second what ghost says - fit new motor assembly, the job is then done forever, for sure!
Another point, when I did mine a few weeks ago, the seized bearings were one problem but also the brass segments of the commutator where the brushes contact was so corroded that the fan still would not run after getting bearings freed. There didn't seem to be any way to access to fix this.

While the dash is off check:-
Resistor for fan motor
Fan switch - this was another problem with mine. They can be disassembled and contacts cleaned
Check with multimeter or 12vdc continuity tester that power is getting to fan on all 3 speeds - before puuing dash back!
Earth crowns and corroded connectors
Tidy any other dodgy wiring

Got scared, I'm ordering a fan from brickwerks! What's the discount code?

pi quattro wrote: brickwerks... What's the discount code?

Details on "how to" HERE

the correct way to remove shear bolts is to drill through the bolt, just as you did.
they are not meant to be re-used.

Funny I posted exactly the same question on the German IG 16" forum a few days ago and was also advised to also:
Look at the windshield wiper mechanics,
consider installing those "double spurt nozzles" od whatever they are called in English (the thingies that squirt warter on the windshield) because it is easier when the dash is off
look for/take care of corrosion in the vent air intake area
look for signs of wear on the upper clutch pedal fixation
and possibly upgrading the power brake unit to a BMW one...

Did this a while back with the help of Dan Hotpod. Here is my thread https://club8090.co.uk/forum/viewtopic.php?f=4&t=106887" onclick="window.open(this.href);return false;

The thread starts as being a bit syncro specific but ends being relevant to all types. Hang on in there as it will be worth it in the end. Get your new blower from BW. Its not expensive and will now probably outlast your van.

ghost123uk wrote:

pi quattro wrote: brickwerks... What's the discount code?

Details on "how to" HERE

Thanks, I did see this but couldnt get the discount applied in time, ho hum!