Hi everone,I purchased in January, a German design Decoupler from Florian Speier in America,and today I got around to installing it.The kit included everything that I needed to install it and instructions.It was a fun job and took me around 5 hours.These are the steps I took.
1. Raised vehicle off ground,dissconnected battery and took off nsr tyre.
2.Loosened middle two nuts and bolts on bash bar,put jack under bash bar/engine carrier.
3.Undo and remove 2 rear bash bar bolts at engine carrier bar,then undo and remove the front 2 bolts for the bash bar under the front diff,then undo and remove the two middle bash bar middle support bolts and nuts.
4.Lower the bashbar/engine carrier.
5.Remove driveshaft.
6.Put jack/gearbox jack under gearbox and undo x6,13mm hex gearbox mount bolts.
7.Lower gearbox,maintaining support with jack.
8.Remove x7,13mm hex bolts,including earth strap,holding rear extension housing,place drip tray under,and remove extension housing.
9.Remove locating dowels and clean gasket mating surface.
10.Remove splined shaft and replace with new supplied gear and fit supplied circlip.
11.Tap in new supplied locating dowels and use sealing compound on new supplied gasket and fit new extension housing/vaccum actuator assembly,tighten x7 13mm hex bolts,evenly.
12.Raise gearbox,tightened x6,13mm hex gearbox support bolts(dont forget the earth).
13.Fill gearbox with the same oil that was in it.(I always use Nulon Synthetic,with a Nulon additive).
14.Find electric plug,behind charcoal cannister,nsr wheel arch,snip 3 cable ties.
15.Find gap between chasis were electrics should run,and with a coat hanger,pull cable and wire through.Spray connector and supplied switch with silicon,connect and pull boot over switch.
16.Attach supplied vaccum lines to the actuator,blue to blue and run up towards the front of bus,tie strap to exsisting wiring loom ns.
17.Remove spare wheel.
18.Remove glove box and dash panels.
My bus already had rear diff lock so the switch panel was already there.
19.Cut hole in rubber grommet in floor,and with coat hanger,pull through x2 vaccum lines.
20.Fit new supplied vaccum swith,cut and tee into main vaccum line(from rear diff lock switch),to vaccum cannister.Then fit to vaccum lines to decoupler actuator.Blue to Blue.
21.Fit supplied globe to instrument panel.
22.Connect battery,start engine,run for one minute,pull decoupler switch,watch for light,check underneath that actuator has switched.
23.Fit tailshaft,then fit bash bar.(dont foget 2 middle bolts on bash bar that you loosened)
24.Check decoupler operation,following workshop manual procedures on testing VCs.
This was an easy job and Florians kit was supplied with everything I needed,fitted exactly and works the way it should,first time.Very good piece of kit.
I am now lucky to have a Syncro fitted with a German design Decoupler,rear wheel bearings next week,and then 91 2.5 Subaru engine conversion in the coming months.Later..
1. Raised vehicle off ground,dissconnected battery and took off nsr tyre.
2.Loosened middle two nuts and bolts on bash bar,put jack under bash bar/engine carrier.
3.Undo and remove 2 rear bash bar bolts at engine carrier bar,then undo and remove the front 2 bolts for the bash bar under the front diff,then undo and remove the two middle bash bar middle support bolts and nuts.
4.Lower the bashbar/engine carrier.
5.Remove driveshaft.
6.Put jack/gearbox jack under gearbox and undo x6,13mm hex gearbox mount bolts.
7.Lower gearbox,maintaining support with jack.
8.Remove x7,13mm hex bolts,including earth strap,holding rear extension housing,place drip tray under,and remove extension housing.
9.Remove locating dowels and clean gasket mating surface.
10.Remove splined shaft and replace with new supplied gear and fit supplied circlip.
11.Tap in new supplied locating dowels and use sealing compound on new supplied gasket and fit new extension housing/vaccum actuator assembly,tighten x7 13mm hex bolts,evenly.
12.Raise gearbox,tightened x6,13mm hex gearbox support bolts(dont forget the earth).
13.Fill gearbox with the same oil that was in it.(I always use Nulon Synthetic,with a Nulon additive).
14.Find electric plug,behind charcoal cannister,nsr wheel arch,snip 3 cable ties.
15.Find gap between chasis were electrics should run,and with a coat hanger,pull cable and wire through.Spray connector and supplied switch with silicon,connect and pull boot over switch.
16.Attach supplied vaccum lines to the actuator,blue to blue and run up towards the front of bus,tie strap to exsisting wiring loom ns.
17.Remove spare wheel.
18.Remove glove box and dash panels.
My bus already had rear diff lock so the switch panel was already there.
19.Cut hole in rubber grommet in floor,and with coat hanger,pull through x2 vaccum lines.
20.Fit new supplied vaccum swith,cut and tee into main vaccum line(from rear diff lock switch),to vaccum cannister.Then fit to vaccum lines to decoupler actuator.Blue to Blue.
21.Fit supplied globe to instrument panel.
22.Connect battery,start engine,run for one minute,pull decoupler switch,watch for light,check underneath that actuator has switched.
23.Fit tailshaft,then fit bash bar.(dont foget 2 middle bolts on bash bar that you loosened)
24.Check decoupler operation,following workshop manual procedures on testing VCs.
This was an easy job and Florians kit was supplied with everything I needed,fitted exactly and works the way it should,first time.Very good piece of kit.
I am now lucky to have a Syncro fitted with a German design Decoupler,rear wheel bearings next week,and then 91 2.5 Subaru engine conversion in the coming months.Later..