Mobieus_uk

after making sure everything is lined up turns out my clutch cable has a shorter distance between the grommet at point A and the bit that sits on the clutch arm at point B, i don't seem to have the extra extension, meaning washers and spacers required as to re-align the arm is a gearbox off job lesson learned always take reference pictures

Hopefully car will be back on the road today, data sheet for gearbox oil states GL4 + synthetic, Ive bought gl5 part synthetic as halfords dont do gl4+, should i change it for gl4 fully synthetic or just stick with the gl5 part synthetic

contact the makers and tell them the car you are fitting it on, they should then provide you some information that tells you which wires you need to connect to in the car or return it and buy a hawk central locking kit, tell them the car and they provide a wiring diagram that relates to your car

I thought i had made a mistake when i fitted the box and had to use spacers to take the slack out of the clutch, I can clearly see now i have put all the spring assembly the wrong side of the clutch release arm, printing off for reference

fun refitting the gearbox, for anyone attempting this you will need a engine hoist and i would recommend ratchet straps as you will have to tilt the box, unless you are lucky enough to have access to ramps and the correct gear, but for a axle stand type of job, you will also have to lower and raise the engine while you wiggle the box in

a quick google has resulted in remote oil filter kits, maybe have a look at those if you can relocated your oil filter you may free up some space somthing along the lines of http://www.ebay.co.uk/itm/MOCAL-REMOTE-OIL-FILTER-KIT-BMW-FORD-FIAT-ROVER-V8-VW-3-4UNF-M20-M18-13-16-FK4-/401131543508?fits=Car+Make%3AVW&hash=item5d654d9bd4:m:mmbzjEpfJq2UwmBMplJvTwQ

cheapest way to buy was from their ebay shop then click and collect £135.64 worked out at about 46% discount 641441690 is the part number for lupo sdi, the number was correct they said that it had been packaged wrong, more likely its been a returned item ,it does not come with a alignment tool so bought one from halfords for about £16, the replacment at least it now fits on the input shaft of the gearbox

yes, they have confirmed its the wrong friction plate so hopefully collect the replacement tomorrow

have you looked at a adaptor plate http://www.ebay.co.uk/itm/OIL-FILTER-SANDWICH-PLATE-FORD-FOCUS-FIESTA-VW-GOLF-PASSAT-BORA-POLO-LUPO-/400659279779?hash=item5d49276fa3:g:9C8AAOSw1ZBUt5Ta

you post suggests you had the problem with the old engine, is it the same head transferred over in which case if the problem has followed you to the new engine it can only likely be the bits you transferred over, if not then unlucky if the new engine has the same problems as the old

bearing kits that i bought came with new hubnuts

from autodata

sidelights are just the illumination circuit, same one that lights the dashboard or your radio, you looked at running a wire from the illumination circuit on the radio?

I may have not explained it properly and i think you replied while i uploaded the pic, but in a nutshell the clutch plate should be about 20.4mm but is about 17mm, the bearing fits on the shaft and sits on the sleeve but the clutch plate does not fit on the input shaft of the gearbox

this might be a dumb question but it relates to the clutch, I'm pretty sure they have supplied the wrong clutch or at least the bits have got mixed up in the box but here is the dumb question, should the clutch release bearing be about the same size hole as the one in the clutch plate, as my bearing looks fine but the clutch plate is way smaller

but no warranty, but i get what your saying and would have loved to have stripped it and rebuilt it but I had to draw the line in the sand on what I am capable of doing without nice workshop facilities and the know how. hopefully it will run well once its all back and fitted, was going to be this weekend but got messed about with the clutch supplier

perfect, thanks guys

Thankyou, picture would be handy for comparison

Thanks Sausage, going by the workshop manual it should be 90degrees,

not sure if my description is correct but the whole mechanism has been removed out of the gearbox and I'm not sure where its rest position is, don't want to get it wrong and changing the position means dragging gearbox out I got a picture off ebay but its not a 1.7sdi box got a picture off ebay which gives me a idea can anyone confirm as it looks like it lines up with the bottom bolt on the support bracket

gearbox rebuilt everything below was replaced

heres the reason things did not work as they should

not sure, will know once i pull the clutch off this weekend

planning to replace the clutch while the gearbox is off, any recommendations i was looking at this http://www.ebay.co.uk/itm/VW-Lupo-1-7-SDi-Dual-Mass-Replacement-Flywheel-Clutch-Kit-/172272884014?fits=Model%3ALupo&hash=item281c43992e:g:kzUAAOSwyDxXhu7Z comes with a a new flywheel and 2 years warranty, or should i stick to just the clutch http://www.ebay.co.uk/itm/232049182649?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT i like the second option as its eurocar parts not a firm thats likely to disappear overnight and the clutch is a Luk which ive heard is a good make

got quote for repair, bearings are trashed and some damage to 2 gears, all in gonna be £505 inc vat, comes with 12 month warranty