The Lucky Client

avatar
(Edited)
Authored by @Technicalside

pixlr_20230509204744289.jpg

IMG-20220820-WA0073.jpg

Well Hello There Fellow Technicians And Hivers

A while back we've got this Volkswagen TSI and at first all we had to repair on the vehicle was the clutch, sounds easy and simple right? Well we did the clutch and fitted the transmission back into place. Then we noticed that the transmission had an oil leak in the weirdest location, at first we replaced a seal from which it looked to be leaking but then it was still leaking oil.

Long story short the client had a cracked casing, and in the spot it cracked it must be that the vehicle was in head on accident, not a worry but the casings tend to crack where they are mounted to the vehicle.

So all in all a simple clutch replacement led to a full tear down to replace the casing.

The downside to all of this is that we had to remove the transmission again in order to fix the problem, we didn't get any extra money for this job, we have a lot of casings lying around so we decided to help the client out a bit and get rid of some junk lying around.

Yes that is a very bad crack and although it didn't pour oil out like opening a tap but over time it would eventually drain the transmission of oil and cause a major failure.

IMG_20221102_101412.jpg

IMG_20221102_101415.jpg

After I pulled of most of the small parts bolted to the transmission and split it from the bellhousing, now keep in mind the clutch had to be removed as well since it's a dual clutch and they get fitted to the transmission and not the flywheel. So at this point I've been busy for a good 20-30 minutes, not including the removal of the transmission which was around an hour and a half.

What needs to happen next is we have to remove all of the cluster shaft in this one, the tricky part is they have to be removed all at once and with the gear selectors included.

IMG_20221102_104033.jpg

As I said all the shafts have to be removed all at once and the use of a hammer is not the best way to get that job done, we have a press and that is probably the best possible way of removing them, now there's two catches to the removal of those shafts the first is that I have to catch all of those gears when they pop free and well those are solid metal gears and they tend to be heavy as hell.

Nothing new in my line of work.

IMG_20221102_104426.jpg

The second catch to this is that none of them can press against something, other wise the gears might break or you might break the press.

Now I know the gear to the right looks like it will be catching the frame of the press but it's actually higher than the rest so it will slide right past, the bearing beneath it on the other hand is the catch we don't want that to break but it's also clearing just enough to pass by.

Although I still like to triple check these things, they can be expensive and although "bossman" probably won't cut it from my pay I still don't like to break things.

IMG_20221102_104444.jpg

See, it's quite a bit of metal that one has to catch when those shafts pop loose from the bearings.

Well those we can leave right there until we've prepared the next casing for them to fit into.

IMG_20221102_110846.jpg

Last but not least we have to pull out the last of the small parts, no use in fitting parts from the second hand casing of which we have no idea if they will leak or are in-fact broken.

I mean after all we are pulling this transmission for the second time. 😅

While they are removed we can do a deep clean of all the parts as well, so this client is really getting his money's worth hey!

IMG_20221102_110927.jpg

IMG_20221102_112724.jpg

Hot Dayum!

When these casings are given a proper washing they certainly look as good as new don't they? Never mind the one to the left I'll clean that later on but for now we will be building into the clean casing.

This is basically going to be a reversal build, when tearing down the transmission down one pulls the bellhousing off first, then when one builds it up again you start building it into the bellhousing, OR at-least that's just the method that we've found the easiest, it is possible to do it the other way around as well.

IMG_20221102_114602.jpg

It's also quite a tricky thing to get all the shafts into the bearings, as all of them have to be going in all at once, much like they have to be removed all at once as well.

Sometimes a third arm would go more than a long way. 😂

IMG_20221102_115041.jpg

Once all of them are somewhat in place they have to be pressed in and once again they all have to move simultaneously to ensure that you don't break a gear selector fork, gear or even a bearing. There are so many things that you have to watch while pressing the shafts into place.

IMG_20221102_120706.jpg

Just a demonstration of what needs to be done.

Back into the press we go!

Well we are almost done with the job, that's to say if we don't break anything while pressing the shafts into place. Oh well let's hope not hey, it's always a gamble when high pressure is applied to anything.

Sorry for the blurry photo.

IMG_20221102_121321.jpg

Pressed right back into place, so now we can get back on progress and get this job done and out of the shop!

Well we aren't really done just yet, we still have to fit the last casing and re-fit all of the small tedious and annoying parts!

IMG_20221102_122238.jpg

Laughs, one can get excited way too fast! You'd think once all of the small tedious parts are fitted you can push this back into the vehicle right?

Well no 😂 I still have the clutch and all that to fit and one needs a few special tools and such, but most of the hard work is done and dusted with. So I can say that I am feeling proud I did this build all by lone some!

IMG_20221103_090432.jpg

Let's Gooooo!

IMG_20221103_090752.jpg


Dated 09/05/2023

Take note this is not a how to guide, merely myself talking about the work I do and my thoughts around certain things.

To everyone who made it this far into my post Thank you for the read and the support.

If you found this entertaining or educational please consider a re-blog and up-vote.

Most of all please leave a input in the comments below, whether is good or bad critic I would like to know, whether its your opinion or your way of doing things in a different manner I would like.

Power House Creatives Logos FINAL.png

Connecting the people of #HIVE across South Africa. #hive



0
0
0.000
4 comments
avatar

Greetings my friend, I am surprised that all the work you did is free, in my country that is not seen, some agreement is reached but not for free.

0
0
0.000
avatar

Wow always your works are echo like in a factory the difference of place where we work and country.

0
0
0.000