Post by Nick on Sept 22, 2012 18:59:00 GMT
as you will all know inside our primary discs lives a rubber disc that helps the gearchange occur in both directions dependant on the throttle position... this is of course a seal between two chambers inside the outer disc ...
THIS is NOT a seal between the outer disc chambers....
This sits on an alloy ring inside the outer chamber which was covered in nasty sharp casting marks
The whole lot is lubricated by ATF fluid , you know.. the red stuff...
This IS NOT ATF but ep of some description going by the sulphurus stink coming from it, and probably why the diaphragm has failed
This is how I locked the front disc to get the bolt done up on the end after refitting the rubber to it and after it had been cleaned out..
the strap is a continuous loop, I locked it around the disc by passing itself through itself and then hooked it up at the back,
I was going to use this to UNDO the nut as well but as it happened it wasnt done up..
also a reason for failure I suspect..
this shows it locking it in the "do up" direction
Finally once the rubber was in place it was a case of adding 100ml of fresh red ATF fluid back into the unit
Only had 10ml syringes so used this one 10 times lol
the locking ring was replaced in stages using some small mole grips as per Mr Horners amazing advice
so in summary
remove guards completely
undo the 2 17mm bolts securing the vario to the car on the side of the primary to be repaired so they are just gripping by a few turns (gives good clearance to get belt off)
remove belt
mark the cover, lock ring, drum in a manner that cant be wiped off so it goes back exactly where it came off from...
ping out lock ring and go round the cover with a mallet tapping it until it comes off,
pull back diaphragm and put a 2mm piece of rod into the hole in the top of the bobweight carrier to stop it coming off the shaft when the centre nut is undone
lock drum using a strap and undo the centre nut - (the bob weight carrier will then go tight on the piece of 2mm rod)
wipe and clean it all out inside
deburr the alloy ring
refit diaphragm
lock drum using strap again and secure the centre nut (and its concave washer) to a setting of 65-72 ft lb (according to manual)
at this point it should release the piece of 2mm rod and you can recover this from inside the vario
peel back top edge of diaphragm and inject 100cc of ATF into the space behind it
replace cover making sure the marks you made earlier match up
starting at the end with the hoop clamp the lock ring into place, work your way round until eventually it is back in place (I had 3 sets of grips and to get the last mm of clearance I used a drift to tap the thing into its groove)
everything else is the opposite of removal , gap your belt accordingly...
drive it like it love it
THIS is NOT a seal between the outer disc chambers....
This sits on an alloy ring inside the outer chamber which was covered in nasty sharp casting marks
The whole lot is lubricated by ATF fluid , you know.. the red stuff...
This IS NOT ATF but ep of some description going by the sulphurus stink coming from it, and probably why the diaphragm has failed
This is how I locked the front disc to get the bolt done up on the end after refitting the rubber to it and after it had been cleaned out..
the strap is a continuous loop, I locked it around the disc by passing itself through itself and then hooked it up at the back,
I was going to use this to UNDO the nut as well but as it happened it wasnt done up..
also a reason for failure I suspect..this shows it locking it in the "do up" direction
Finally once the rubber was in place it was a case of adding 100ml of fresh red ATF fluid back into the unit
Only had 10ml syringes so used this one 10 times lol
the locking ring was replaced in stages using some small mole grips as per Mr Horners amazing advice
so in summary
remove guards completely
undo the 2 17mm bolts securing the vario to the car on the side of the primary to be repaired so they are just gripping by a few turns (gives good clearance to get belt off)
remove belt
mark the cover, lock ring, drum in a manner that cant be wiped off so it goes back exactly where it came off from...
ping out lock ring and go round the cover with a mallet tapping it until it comes off,
pull back diaphragm and put a 2mm piece of rod into the hole in the top of the bobweight carrier to stop it coming off the shaft when the centre nut is undone
lock drum using a strap and undo the centre nut - (the bob weight carrier will then go tight on the piece of 2mm rod)
wipe and clean it all out inside
deburr the alloy ring
refit diaphragm
lock drum using strap again and secure the centre nut (and its concave washer) to a setting of 65-72 ft lb (according to manual)
at this point it should release the piece of 2mm rod and you can recover this from inside the vario
peel back top edge of diaphragm and inject 100cc of ATF into the space behind it
replace cover making sure the marks you made earlier match up
starting at the end with the hoop clamp the lock ring into place, work your way round until eventually it is back in place (I had 3 sets of grips and to get the last mm of clearance I used a drift to tap the thing into its groove)
everything else is the opposite of removal , gap your belt accordingly...
drive it like it love it
