Re: My New CF

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Post by Phil Bradshaw » Club admin » Wed Sep 05, 2018 9:38 pm
Joined: Sun Sep 02, 2012 7:15 pm
Posts: 3732
Rear mounting location for Vauxhall transmission -

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Overdrive I think uses a mounting with holes rather than x2 5/16-inch studs top side (similar to automatic transmission mounting).

I can't remember which way around is best for the lower stud for overdrive: suck it and see, juggle cross member position on chassis bracket if need be - it might fit better with the 4 bolts in previously unused threaded holes. Clean out threads using a 3/8-inch UNF tap - original thread chaser bolts can jam in rusty threads.

Torque reaction bar (rear view, ZF transmission - bar position and bushes arrangement identical for Vauxhall transmission) -

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Spacer (3) is to achieve some compression of the bushes on assembly. Spacer (5) sets the alignment (horizontal or thereabouts - fix soft or sheared left side engine mounting first).

Overdrive wiring is supplied from the ignition switch.

If there are two wires coming out of the harness along the chassis longitudinal forward of the fuel tank then the green one should be overdrive supply; green+brown is for reverse lamps using the same supply.

If no wires present then pick one of the fuses with green wires to it for ignition supply (fuse 3, 4, 5 or 6 in 12-way fuse box).

Supply for overdrive should go to the inhibit switch in the reverse stop housing opposite the gear shift turret.

Wire from second terminal on inhibit switch should go to the gear shift lever switch; return from the switch then should go to the overdrive solenoid supply wire.

There should be an earth wire from the solenoid or adjacent bolt to the nearest chassis brace.

Inhibit switch position should ensure that overdrive only can be used in 3rd and 4th gears.

Reverse lamps switch on the gear shift turret should be connected between ignition supply (green) and the green+brown wire if present.

Mounting nut for switch should be welded to the turret side cover; slacken lock nut to adjust switch to work only when reverse selected.
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  • What is real is not the external form but the idea, the essence of things. Constantin Brâncuși

Re: My New CF

Post by MattA24 » Subscribing Member » Thu Sep 06, 2018 11:33 pm
Joined: Wed Jan 15, 2014 9:06 pm
Posts: 203
I whipped the gearbox cross-member off of the spares van today. It really highlighted how beaten up and twisted the one on the new van is.

After lots of trial and error and I got better cross-member on and lined up roughly with the gearbox mount. It's still not in perfect alignment, but I'm hoping it will sit a bit better once I've renewed the engine mountings (well done Phil, you're quite right - the left one looks rather sad).

If that doesn't smarten it up the position of the gearbox mounting (which really wants to sit a fraction further forward), reckon I'll be ovaling one of the holes on the cross-member... :lol:

(Phil - I took a goosey at those other handy pre-threaded holes in the chassis but they were well out of scope for this particular setup, thanks though)

My mk1 eyeball (to quote Phil again) says the transmission's output is perhaps a bit closer to the floor of the van than I'd expect. I'm assuming I want to end up with my gearbox's output should be near-enough dead in-line with the prop centre baring? :?:

(not the end of the world, as I'm fitting a transit centre baring on a custom bracket)

Cheerio!
Matt

Re: My New CF

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Post by Phil Bradshaw » Club admin » Fri Sep 07, 2018 12:32 am
Joined: Sun Sep 02, 2012 7:15 pm
Posts: 3732
As long as nothing is too much out of alignment for bolting everything together getting the propellor shaft more or less in line with the centre bearing give or take a few degree should be right enough.

Likely when a new left side engine mounting is on things will move a bit anyway. Temporarily fit the cross member to support the transmission while changing the engine mounting so that the engine can't fall backwards when jacked up.

Apart from the rear mounting (studs or through holes top side) there isn't any difference I can think of between overdrive and non-overdrive mounting arrangement.
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  • What is real is not the external form but the idea, the essence of things. Constantin Brâncuși

Re: My New CF

Post by MattA24 » Subscribing Member » Fri Sep 07, 2018 12:42 am
Joined: Wed Jan 15, 2014 9:06 pm
Posts: 203
Phil Bradshaw wrote:
Fri Sep 07, 2018 12:32 am
Apart from the rear mounting (studs or through holes top side) there isn't any difference I can think of between overdrive and non-overdrive mounting arrangement.
... which is why it's so darn strange that it was such a botched-about installation, bad enough to shred the centre bearing cushion. But anyhow, I think i'm on the right track again now.

Hopefully some new engine mounts will tidy everything up nicely. There seems to be lots of sets on ebay (some of which surprisingly claim to fit every CF)

Cheers again,
Matt

Re: My New CF

Post by MattA24 » Subscribing Member » Thu Sep 13, 2018 8:24 pm
Joined: Wed Jan 15, 2014 9:06 pm
Posts: 203
Hello again,

I went and took a crack at the engine mounts today. The passenger side one was very sad, and tricky to get off because the rubber had squished so much that it enveloped some of the mounting bolts. Eventually I managed to get a spanner onto them and cracked them off. Here's the old squishy one vs the new one:

Image

The driver's side one looked okay, but I changed it too because they come in pairs. This one turned out to be a total pig because the replacement wouldn't wiggle down to the bottom of the slot in the chassis mount for love nor money. Ended up sending it home with a lump hammer and iron bar.

To my great delight, (and as Phil predicted) with the engine mounts changed, the troublesome gearbox mount stud suddenly lands in exactly the right place! :D :thumb: :brew:

With all these mountings set up nicely, the sleeve output on the back of the overdrive is now definitively sitting too high for the centre bearing. This leads to an interesting question that I expect has no best answer... Do I either:

1) Raise the centre bearing? I'm fabricating a bracket for a transit bearing anyhow, so I can just fabricate it to fit where the gearbox has ended up.

2) Lower the transmission output? I've got some spacers that previous owner made to go between the gearbox cross-member and chassis, presumably for exactly the same reason.

What would you do? :?:

-------------------------

Another big job took place last weekend. We demounted the camper box, with extreme prejudice:

Image

Nothing of value was lost.

Re: My New CF

Post by RobX » Subscribing Member » Thu Sep 13, 2018 8:38 pm
Joined: Fri Aug 12, 2016 8:52 pm
Posts: 126
Wow. I just used hammers and an angle grinder. Looks like you used explosives!

Re: My New CF

Post by MattA24 » Subscribing Member » Thu Sep 13, 2018 9:03 pm
Joined: Wed Jan 15, 2014 9:06 pm
Posts: 203
We used a sledgehammer and a pickaxe. I got some energetic friends around and told them to go at it as they thought best.

Probably looks like such a mess because every single bit of timber was rotten through and exploded into matchwood as soon as we tapped it with the sledgehammer.

RobX, let me know if you find any good ally sheet suppliers. And by good, I mean cheap!

Re: My New CF

Post by RobX » Subscribing Member » Thu Sep 13, 2018 11:00 pm
Joined: Fri Aug 12, 2016 8:52 pm
Posts: 126
I've given up an aluminium sheet. Today I learnt that the maximum size for a sheet is 3m x 1.5m unless you're buying large quantities, and that the kind of seams I would need are a bit specialist too. Given my camper's 4.8m at it's longest, that would mean vertical and horizontal seams... scary stuff.

So I'm going back to plan A which was to use ACM (this stuff). A sheet can go from top to bottom, and I just need to figure out how to butt join the sheets. I'm thinking either a millimetre or two gap filled with Sikaflex 512 or Wurth Bond & Seal, taped over with aluminium tape; or glue some kind of T-bar into and over the gap.

Re: My New CF

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Post by Phil Bradshaw » Club admin » Thu Sep 13, 2018 11:06 pm
Joined: Sun Sep 02, 2012 7:15 pm
Posts: 3732
How much is the transmission tailshaft too high for the centre bearing?

I have a feeling that the overall length of the transmission with and without overdrive may be behind the height difference and tipping the front shaft up at the front will slightly reduce the operating angle of the front joint of the rear shaft (a Good Thing) without necessarily harming the centre bearing cushion.

If the angle of the front shaft is small then suck it and see: shaft will vibrate soon enough if the angle is too great.
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  • What is real is not the external form but the idea, the essence of things. Constantin Brâncuși

Re: My New CF

Post by MattA24 » Subscribing Member » Thu Sep 13, 2018 11:15 pm
Joined: Wed Jan 15, 2014 9:06 pm
Posts: 203
Rob, isn't ACM the stuff that burnt so undesirably in various towerblocks? I'm sure they're delighted that someone still wants to buy some!

I noted the 3 x 1.5 max size too for ally, but you see a gazillion older Luton vans out there with vertical and horizontal seams between sheets that don't leak. The seems are just an inch of overlap about the rivits.

Out of interest how much are you being quoted for the ACM?

Phil, I'm afarid I can't work out what course of action you're advocating :?

The current setup would require the centre bearing around an inch higher up to get the front shaft running dead straight.

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