CX clutch change
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  1. #1
    Real cars have hydraulics DoubleChevron's Avatar
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    Default CX clutch change

    He we go.... pictorial progress of the CX (I may need it to put the bloody thing back together ).

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    clutch change

    seeya,
    Shane L.
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  2. #2
    CitroŽn, what else? smiffy1071's Avatar
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    Quote Originally Posted by DoubleChevron
    He we go.... pictorial progress of the CX (I may need it to put the bloody thing back together ).

    clutch change

    seeya,
    Shane L.
    Thanks for taking such a detailed description, this will really help me when I do mine! Last time I drove my turbo was in April 2004, and it was starting to slip a bit in 3rd, but only if I gave it heaps! john s
    2005 C5 2.0 VTR Hdi 138, 1986 Kawasaki GPz 750G2

  3. #3
    Moderator Alan S's Avatar
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    Shane,

    What a fantastic write up. Must have almost taken as long to take the pics as it did to do the job and I must admit, these days I would have forgotten what I was going to write by the time I got around to uploading the pics.

    Couple of points from the book of experience for future reference.

    With that bearing on the camshaft; in future, apply the puller as you did, but then give the outside of the bearing a nice bead of weld around the outside, apply a bit more pressure to the puller, go have a cuppa and by the time you come back, it's either loose or another bit of extra pressure and/or a tap on the end of the bolt on the puller should see it off.

    Also before you try to reassemble, goto e-Bay and buy one of these:




    Normally sell for around $25 - $45 and worth every penny; use one and you'll never use a chain again. You can drop an engine in at around 70 degrees if you need to (as with some BXs) and it's here:

    http://cgi.ebay.com.au/ws/eBayISAPI....sPageName=WDVW



    As a final thing, maybe we could have this put in the Humour Forum with an < R > rating?



    We all know what your thoughts are on CXs but isn't that taking it a bit far??


    Again, in all seriousness; great write up.



    Alan S
    If it ain't broke, use a 12" shifter.....that usually does the trick!!

  4. #4
    1000+ Posts cruiserman's Avatar
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    Geeze there is some rust on the pressure plate. You should invest in some HT chain no need for the string then as it wont break under 3.5 times its rated SWL with 8mm chain rated at 7ish tonne it is a good investment as gonad gal chain is an unknown quantitiy.
    Neil
    '94 405 SRBT

    '82 CX 2400 Pallas 5spd

    '77 CX 2400 Pallas 4spd manual Import

    '76 CX Super

    '05 WL Statesman

    '92 HZJ80 Landcruiser

  5. #5
    Real cars have hydraulics DoubleChevron's Avatar
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    Thanks Guys,

    Alan I thought those load levellers were about $90bux.... If I can get one for $25 most certainly I'd get one in a heartbeat (I simply couldn't afford another $90 at the moment).

    Alan, Ang said exactly the same thing about that photo above .... hmmm.... Maybe I'll have to rethink that one

    seeya,
    Shane L.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  6. #6
    CitroŽn, what else? smiffy1071's Avatar
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    What was it someone was saying about having a webcam in your shed? I think it would have to be a restricted access one!!!john s
    2005 C5 2.0 VTR Hdi 138, 1986 Kawasaki GPz 750G2

  7. #7
    Real cars have hydraulics DoubleChevron's Avatar
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    Alan I just looked up leveler on ebay. Check this out:

    http://cgi.ebay.com.au/ws/eBayISAPI....sPageName=WDVW

    crane, jack stands and seperate mobile engine stand.... All for $250bux Bugger me, that's the 2ton engine crane I have too !!!

    Who in there right mind would stuff around with a block and tackle when you can get these things so cheap now !!!

    seeya,
    Shane L.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  8. #8
    Moderator Alan S's Avatar
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    Quote Originally Posted by DoubleChevron
    Alan I just looked up leveler on ebay. Check this out:

    http://cgi.ebay.com.au/ws/eBayISAPI....sPageName=WDVW

    crane, jack stands and seperate mobile engine stand.... All for $250bux Bugger me, that's the 2ton engine crane I have too !!!

    Who in there right mind would stuff around with a block and tackle when you can get these things so cheap now !!!

    seeya,
    Shane L.
    That's what I've been trying to tell some of these guys for about 12 months now.
    With these FWD cars even for other jobs that don't include motor removal, they're a must.
    I used mine (including leveller) when we rebuilt the slasher, I also used it to move a CX minus mechanicals across the garage and used it on two cambelt jobs. Magic.
    Those levellers are priceless though; until you use one, you can't appreciate just what a necessity they really are. They take all the heave ho and risk of falling or damage out of any lifting job.

    Alan S
    If it ain't broke, use a 12" shifter.....that usually does the trick!!

  9. #9
    Real cars have hydraulics DoubleChevron's Avatar
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    I just thought of something. Those load levers are rated at 500kgs. Doesn't the CX lump with the gearbox attached come bloody close to that

    seeya,
    Shane L.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  10. #10
    Moderator Alan S's Avatar
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    Quote Originally Posted by DoubleChevron
    I just thought of something. Those load levers are rated at 500kgs. Doesn't the CX lump with the gearbox attached come bloody close to that

    seeya,
    Shane L.
    Not quite; when I imported that car in a box a few years back I think it may have gone around 400 with a few other items included, so probably closer to 350 than 500.

    Alan S
    If it ain't broke, use a 12" shifter.....that usually does the trick!!

  11. #11
    Real cars have hydraulics DoubleChevron's Avatar
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    Quote Originally Posted by Alan S
    Not quite; when I imported that car in a box a few years back I think it may have gone around 400 with a few other items included, so probably closer to 350 than 500.

    Alan S
    Even 400kg should be ok (after all I'm not getting under the bloody thing. If it was right on 500kgs.... Not worth the risk ...

    thanks
    Shane.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  12. #12
    1000+ Posts cruiserman's Avatar
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    Is it a max load rating or a SWL rating, SWL has a factor of 3.5x in it.
    Neil
    '94 405 SRBT

    '82 CX 2400 Pallas 5spd

    '77 CX 2400 Pallas 4spd manual Import

    '76 CX Super

    '05 WL Statesman

    '92 HZJ80 Landcruiser

  13. #13
    Real cars have hydraulics DoubleChevron's Avatar
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    Quote Originally Posted by cruiserman
    Is it a max load rating or a SWL rating, SWL has a factor of 3.5x in it.


    No idea. It looks quite well made in the photos. Imagine it's just refuse to slide (as opposed to break) if it was overloaded.

    They have just halved the allowable weight for the 2tone crane in one ebay add, so possibly they have been required by law to update the ratings to SWL standards.

    seeya,
    Shane L.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  14. #14
    Moderator Alan S's Avatar
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    Mine didn't complain about picking an entire car up, so I don't think there's a real & immediate danger.

    Alan S
    If it ain't broke, use a 12" shifter.....that usually does the trick!!

  15. #15
    Real cars have hydraulics DoubleChevron's Avatar
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    Quote Originally Posted by Alan S
    Mine didn't complain about picking an entire car up, so I don't think there's a real & immediate danger.

    Alan S
    I grabbed a 750kg leveler from the local "cheap tools" place on the way home at luchtime. $35bux .... Gee's I'm bloody sure they were closer to $100bux a year or so ago. For $35bux I'm not risking damage to me or the car trying to wiggle the b@stard back into that hole.

    seeya,
    Shane L.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  16. #16
    Moderator Alan S's Avatar
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    Give us a report on your opinion of it after you've used it.


    Alan S
    If it ain't broke, use a 12" shifter.....that usually does the trick!!

  17. #17
    UFO
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    CitroŽn Tragic UFO's Avatar
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    Quote Originally Posted by DoubleChevron
    For $35bux I'm not risking damage to me or the car trying to wiggle the b@stard back into that hole.

    seeya,
    Shane L.
    Ah! So that's what you were trying to do here:





    And only $35 bucks! Does PYC on the rego stand for Pretty Young Chickybabe?
    Craig K
    2009 C5 HDi Exclusive

  18. #18
    Fellow Frogger! 123abc's Avatar
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    hmmm, 35 bucks is a lot cheaper then what hare and forbes wanted.....................i took one look at theirs and said "nah, nope and no-way"

    made my own at work, even got it officially checked by the engineer just for a laugh

  19. #19
    Real cars have hydraulics DoubleChevron's Avatar
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    Progress...

    Driveshafts done ...
    Re-wiring almost finished. See the before and after shots of the wiring harnesses below.

    seeya,
    Shane L.
    Attached Thumbnails Attached Thumbnails CX clutch change-yukwiring.jpg   CX clutch change-motorwiring.jpg  
    Last edited by DoubleChevron; 13th July 2005 at 11:06 AM.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  20. #20
    Fellow Frogger! briz205's Avatar
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    Shane,

    Will there be pages 9 and upwards. Its actually a very good read. May I also ask what time frame this has been done in?

    Cheers nick
    Auckland NZ -
    2000 Peugeot 406 Coupe, Dark Green.
    2001 Renault Clio Sport RS, Silver.

    Brisbane Aus -
    1989 Peugeot 205 GTi, Light Blue.

  21. #21
    Moderator Alan S's Avatar
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    Can I ad a bit of a suggestion?

    You make my blood run cold using allen keys jammed in the ring end of a combination spanner. because inevitably, you'll round a head out sooner or later.
    I don't know when the next birthday's due and Christmas is still a fair way off, so you may have to get these for Ang for her birthday and ask her if you can use them....if need be, drop a hint for a set of allen keys with a 1/2" socket drive. This way you can even use a torque wrench on them and if need be, give them a clout with a hammer to be sure they're seated before applying pressure with a wrench.
    I saw a certain guy very close to me take out the retaining bolt on the tensioner on a 16V engine once due to it getting skewed when it was put in and then required a piece of steel welding to it to remove it, so it's easy done.


    Alan S

    P.S. I think my set cost me around $12.99 at SuperCheap
    If it ain't broke, use a 12" shifter.....that usually does the trick!!

  22. #22
    Real cars have hydraulics DoubleChevron's Avatar
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    Hi Alan,

    Yep, your not wrong about the Allan key .... Luckily those bolts have nice deap heads. I will need to look at the Sunday market for some allan key socket sets (I have the one to remove the BX starter, but it was the wrong size).

    Nick, in time there will be more pages. The car needs to be back together by this weekend. I've been driving my mother inlaws car while she's away, and she's back next week.

    Time taken (keep in mind this is a UK car) and I've never removed the enigine/gearbox from a turbo model before:

    --A Good day to remove the motor and gearbox (next time it would probably be half a day).
    --2hours to test/dismantle and re-brush the alternator and bench test it(didn't install new bearings).
    --1hour to whip the starter apart and check it
    --4hours to split the engine/gearbox (remembering I had to make up a puller) (next time it'd probably take 20minutes)
    --3hours to put new boots and the driveshaft and cut the old intermidiate bearing off and fit a newie (next time it'd be an hour tops).
    --4hours+ installing new terminals on the engine harnesses while cutting out any copper rot if found. Then containing the wiring in new plastic harnesses
    --several hours wirebrushing and painting anything I found rusty (ie: brackets/levers, mounting hardware, heat shields).
    --4 hours to rebuild radiator fans (an hour tops next time around).

    It's all the little things that take the time. If I'd just thrown a clutch at it and bolted it back in I would have been driving the car again a week ago (my spare time is very limited).

    I still need to:

    --whip the flywheel off and put another crank seal in while I'm here
    --fit the clutch
    --re-assemble everything
    --wire brush, clean and paint the HP pump, regualtor and brake accumular housings (they are a rusty brown colour --should be green).

    I also checked the front drivers suspension before I pulled it apart (the only corner I haven't rebuilt). It desperatly needs ball joints/bushes. It'll be done when I see some lower arm bushes on ebay (I've already got the ball joints from ebay for between 1 and 5 pounds).

    seeya,
    Shane L.
    'Cit' homepage:
    Citroen Workshop
    Proper cars--
    '85 Series II CX2500 GTi Turbo I
    '63 ID19 http://www.aussiefrogs.com/forum/showthread.php?t=90325
    '72 DS21 ie 5spd pallas (last looked at ... about 15years ago)
    '78 GS1220 pallas
    '92 Range Rover Classic ... 5spd manual.

    Yay ... No Slugomatics


    Modern Junk:
    '07 Poogoe 407 HDi 6spd manual

  23. #23
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    Quote Originally Posted by Alan S
    P.S. I think my set cost me around $12.99 at SuperCheap
    I looked in our local SuperCheap a couple of weeks ago - no go. I need 'em for the starter job on the Mi. Maybe the stock varies branch to branch or they've stopped stocking them.

    Stu


    2003 PEUGEOT 206 GTi

  24. #24
    Moderator Alan S's Avatar
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    NBormally have them in stock up here I've found.
    If you ask the counter staff, they can usually look up on the computer what's in stock and where or when stock is due to arrive and price.
    Torx are a bit hard to get there but allen head are common

    Alan S
    If it ain't broke, use a 12" shifter.....that usually does the trick!!

  25. #25
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    Will do - I was actually going to, but the day I was in there, the girl behind the counter had one eye looking at the other, and I didn't want to disturb her.


    2003 PEUGEOT 206 GTi

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