Puma 1.7 Rebuild Mk II

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Post by raggamuffin » Mon Apr 08, 2019 1:11 pm

Hi all,

Quoted £400 to do both arches, cut away metal, replace, respray and waxoyl.

Windscreen to be replaced on Wednesday. £95 excess - bugger.

MOT booked for Thursday for £45.

TBC on when the bodywork can be done. Hopefully in a week or 2. He said it wasn't bad at all and it wouldn't fail it's MOT because of it. All in all he said it was in very good condition, so that's a relief.

The low RPM judder is improving and just in general the drive feels much smoother. It's a little wallowy in 2-3k RPM I'm not sure if this is the cams or the possible sensor issue. It's fine though, just keeping it above 2750 and there's plenty of beans to go around. I still can't get over the grip though. I wonder what it'll be like with the struts and polys installed.

Ed
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Post by raggamuffin » Mon Apr 08, 2019 4:39 pm

Just went on my lunch break. Got back and noticed a puddle in my parking space.

Took a look underneath and it's looking oily.
P02.jpg
p01.jpg
Ideas? I'm going to ring J.

I've put it in another parking space to see if this puddle was from my car.

Ed
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Post by Wild E. Coyote » Mon Apr 08, 2019 4:43 pm

I would bet he put in the oil breather wrongly. The arrow has to point forward, i.e. in the direction of travel
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Post by raggamuffin » Mon Apr 08, 2019 4:57 pm

OK, I'm awaiting a reply from him now. Is it a quick fix? Would the oil need draining?

I don't recall any puddles in the road outside my house. It is a lot warmer today.

Ed
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Post by raggamuffin » Mon Apr 08, 2019 5:16 pm

J said he thought it might be the drive shaft seal. I recommended what you said too.

On a side note, whilst I was under the car I noticed this on the passenger side, just behind the wheel arch. I'm hoping it's nothing too serious but it looks quite bad.

I might ask the bodywork repair guy to just go at the bodywork hammer and tong and ensure the rust doesn't come back. I don't really want to leave anything to chance when it comes to rust.
P03.jpg
P04.jpg
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Post by Wild E. Coyote » Mon Apr 08, 2019 5:52 pm

raggamuffin wrote:
Mon Apr 08, 2019 5:16 pm
J said he thought it might be the drive shaft seal. I recommended what you said too.
Don't think it is a seal as the frontal area of gearbox is covered in oil. On top of the gearbox is the breather that enables the gearbox to 'breathe'. It shoud allow for the air to circulate, but not the oil. If it is put in wrongly, the oil will go out. That looks like it. It is a very easy fix, just installing it correctly.
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Post by raggamuffin » Mon Apr 08, 2019 6:21 pm

Thanks, I'll insist he checks both, or just take it to somewhere else completely and ask them to check both.

I'll keep you posted.

Ed
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Post by raggamuffin » Mon Apr 08, 2019 6:34 pm

Just waiting to see if it can be looked at today or tomorrow. I'd like it fixed before MOT is due on Thursday. Plus on Wednesday the windscreen is being replaced and they gave me a convenient window of 8am to 5pm for when it could happen. :?

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Post by raggamuffin » Mon Apr 08, 2019 6:56 pm

Puddle is slowly getting bigger. Very small though - a fraction of the size of the other puddle.

Not sure if J can look at it tonight. has to be tonight or tomorrow though. I'm guessing it'll be fine to drive for the next 48 hours provided when it's parked up the leak doesn't look massive?

Ed
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Post by raggamuffin » Mon Apr 08, 2019 7:13 pm

Ok, he's coming to have a look at it tonight at 20:30.

Ed
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Post by Wild E. Coyote » Mon Apr 08, 2019 7:19 pm

Well if it leaks while the car is stationary, it is not the breather. It would be spitting oil only on usage. Thsi would indicate the J diagnosed it correctly as failing driveshaft seals (what would imply to me that he was well aware they were od inadequate quality/condition in the first place). They cost so little, it really makes no sense on reusing them....
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Post by raggamuffin » Mon Apr 08, 2019 7:21 pm

He said he had to take the drivers side drive shaft out and it was already quite oily round the seal. After the rebuild he topped up the gearbox oil and said it's probably leaking again.

This isn't going to be leaking so much oil that the car will be unusable will it? I wonder if it's a part that'd be in stock for next day delivery. :|

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Post by st220kyle » Mon Apr 08, 2019 7:59 pm

These parts are easily available and common across most of the ford ib5 box range, probably cost you less than £10 for the seal
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Post by raggamuffin » Mon Apr 08, 2019 9:20 pm

He's just left. He noticed one of the jubilee clips on a coolant pipe was very old and was causing a small leak of coolant. He thinks that this is what most of the leak on the floor was from. He refitted and tightened that and said to keep an eye on it and if needs be he can replace the clip.

He noticed some oil on the top of the transmission. He smelt it and said it was definitely gearbox oil. When he showed me the smell it made me realise, I think i've been smelling this in the car when it's been running for a while... I can't recall his exact wording as a lot of the technical terminology goes over my head. But when he had one of the shafts out, there wasn't much oil that came out of the gearbox. When he filled it up he's not sure if a little extra might've been put in which has caused it to leak. So I don't know at this point, it wasn't really the answer I was looking for and didn't put my mind at ease. I wasn't sure about getting a second opinion at this point.

I'm glad the coolant pipe is fixed, but the gearbox remains an issue. He said the rattle is quite bad. As the clutch has been done within the past 10k miles he doesn't think it would be the clutch release bearing which is what Chris at LMS and a friend of mine thought it might be. I had queried before about buying a used, low mileage gearbox on eBay. He said there's no real guarantees how good a condition it will be in, and it's a fairly long process to take one out and fit a new one. But a gearbox recon and a new clutch and clutch release bearing plus installation would probably cost me in excess of £1000.

So i'm not sure at this point - I'll admit, I started the day on a high thinking I'd been making real progress on the project, and now - well I feel extremely down in the dumps to be honest. J is off on holiday on Thursday and back on Monday. He said Wed/Thu he's not working and could work on the car for most of the day. Sort the lambda sensor, cold air induction, door cards and strut braces. He said he has plenty of clips for the door cards. So there's a positive, but the upcoming MOT, the leak and the rattle feel like big problems right now, with no visible solution.

I'm totally stuck with what to do at this point. J is off on Thursday, the other guy I have used before on my last Puma isn't back until next week from a holiday either. I wonder if I should ask a local garage to look at it and ask about the VSS and the oil breather? At this point I'm thinking the car will fail it's MOT on Thursday. It's idling isn't smooth, it regularly stalls if you don't put the revs on whilst it's stationary, when its going along it doesn't sound smooth at all. Whether this is the gearbox rattle or something else I've no idea. It sounds so unrefined it's almost like I'm driving a diesel. When I try to drive economically it hits the lower rev range where it starts kangerooing and juddering, the fuel economy is absolutely atrocious. I'm left thinking to myself what a whole waste of time and effort this entire project is starting to feel like. But this is my only car now - I've put in too much money to give up now. I just wish the excitement had lasted a little longer. When the car is driven hard it's smooth and a delight, but I can't afford to drive it in high revs and throw it around corners all the time otherwise the running costs and eventual wear and tear would be astronomical

I really feel stuck at this point guys. I know J wants to see this through with the additional work and get the car running well. I know he means well. Having no knowledge of the mechanics doesn't really help me. It just makes me worry about things that I have no way of fixing other than throwing money at the problem and hoping it gets fixed.

Bloody hell..

Ed
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Post by raggamuffin » Mon Apr 08, 2019 11:38 pm

So it turns out a gearbox bearing wouldn't fail an MOT. The leak might if it's considered big enough. An old work colleague who's an engineer suggested cleaning it as best as I could before putting it through it's MOT.

With that, I feel a little less despair.

Progress :|

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Post by Wild E. Coyote » Tue Apr 09, 2019 6:53 am

Regarding cleaning: use brake cleaner and all the oil will be off in seconds.

Regarding the engine issues, is your timing right? There is a special procedure for setting up the timing tensioner, is J aware of it? If he just bolted the tensioner without following the pin procedure (plenty of info here about the proper timing procedure for the 1.7 engine) the engine could be out by some small margin and work rough
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Post by raggamuffin » Tue Apr 09, 2019 7:18 am

I'm going to a local garage today. I'm going to mention all the things you've recommended and get them to work on the car. I know J meant well and wants the car up and running properly, but I think it needs to go elsewhere for a second opinion. Mainly to give me piece of mind, I know J is a good mechanic, but the advice on here and then the advice J gives me often seems conflicting. So a second set of eyes on the problem might offer alternative solutions, plus they offer a courtesy car too.

Thanks for the tip on the brake cleaner. I'll get some today and do that before the MOT on Thursday. I'll mentioned the clutch sensor, VSS and timing regarding the engine issues. Then the gearbox mount, slave cylinder, oil breather and driveshaft seal for the gearbox issues.

As for the timing, Justin said he'd read up about it all before doing it

Ed
Last edited by raggamuffin on Tue Apr 09, 2019 9:23 am, edited 1 time in total.
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Post by raggamuffin » Tue Apr 09, 2019 8:39 am

Garage I went to seemed rather clueless, I didn't get a good feeling about them at all. They also said they'd be hesitant to do any work on a non-standard engine.

Got back home and the puddle is a lot worse.
thumbnail_IMG_20190409_083337.jpg
Ed
Last edited by raggamuffin on Tue Apr 09, 2019 9:24 am, edited 1 time in total.
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Post by raggamuffin » Tue Apr 09, 2019 8:49 am

Garage near where I work said they can have a look at the leak today, to at least give me an idea where it's coming from and what would need doing. They also offer a courtesy car, so if needs be I wouldn't be stuck. They said they'd get it on the ramp and look at it while I wait. With any luck I'll get a confirmation of a specific time for the windscreen to get looked at tomorrow so then I could potentially drop it off at the garage to get the leak fixed.

I think the leak is most crucial to get fixed at this point. Once that's done and the MOT is done I can then focus on the judder and the gearbox ticking. All going well, those will be fixed in time for the bodywork to then be repaired.

Ed
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Post by raggamuffin » Tue Apr 09, 2019 3:08 pm

J told me he's free at midday so I went to his as he said I'd be overcharged ar a garage. I know he wants the work. I did feel a bit more at ease after visiting and it seems his time keeping now is spot on.

New jubilee clip put on coolant hose. J said its lost around 100ml of gearbox oil. He said he thinks he might have overfilled it as it was coming out the top out the breather.

He said the transmission was caked in old oil and said this probably has leaked before. He knows a guy who specialises in Ford gearboxes and will find out if he's got a puma ib5 and a recon kit. I'm asking about buying a driveshaft seal as well in the mean time. He said for now the gearbox will be fine and he cleaned it all up with degrease.

Lamda and cold air induction delivery still tbc.

Other than that, no other updates really. Windscreen tomorrow. Eta still not confirmed they said they'd send a text with a specific time. They sent a text saying between 8am and 5pm. So I'll leave the car at work and go into town I guess

Ed
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Post by Wild E. Coyote » Tue Apr 09, 2019 4:48 pm

Ok, getting there. Slowly, but getting there! :ok:
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Post by raggamuffin » Tue Apr 09, 2019 5:31 pm

I got the driveshaft seals just in case. I'll just ask him to fit them. Tempted to do the same for the VSS.

Awaiting a reply about the gearbox. I'm glad we met up regularly and chatted though. Turns out we've got a lot of similarities and interests which is nice to see. I think it's helped things go smoother and prevented the delays.

Going to have to do a 14 hour shift at work tomorrow. Windscreen repair is still between 8am and 5pm so I figured I'd just go in for 8am and work until 10pm. MOT on Thursday, so fingers crossed for that one. Apparently this guy is a little "lenient" shall we say. Plus i'm dropping it off at Smokey's (the guy who'll do the bodywork), this guy looks like he's been lifted out of 1969. Old school hippie lol. Meeting him again means I might get an idea on when the bodywork can be sorted.

It's all coming together now.

Ed
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Post by Wild E. Coyote » Tue Apr 09, 2019 6:03 pm

raggamuffin wrote:
Tue Apr 09, 2019 5:31 pm
I got the driveshaft seals just in case. I'll just ask him to fit them. Tempted to do the same for the VSS.
Check the wiring first! And connectors.
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Post by raggamuffin » Tue Apr 09, 2019 6:33 pm

Hi,

I've found a guide to where it is.

http://www.pumapeople.com/forum/index.p ... opic=98605

Could be tricky with the new inlet manifold, but i'll give it a look now.

Ed
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Post by raggamuffin » Tue Apr 09, 2019 6:52 pm

It's definitely not where it was shown to be in the pictures. I guess it's been relocated due to the new inlet manifold being installed. I couldn't see where it was and I don't have a jack to get under the car to see where it's been relocated to.

The leak is tiny now by the way. So there's something positive.

Ed
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