Syncro on easter - afterthoughts :)

1

Hey guys.


We've been on the Fraser during last easter holidays. We had a great time and it was also a good test for our syncro.

We got bogged a couple of times on the deep wheel tracks because of lack of ground clearance of the van. No worries, as we were travelling in a group so got it out with a gentle pull with a snatch - nothing too aggressive. Anyway, we've decided to do something about it. At the moment, I have 200mm clearance at the lowest point (bash brackets under the engine) and about 220mm everywhere else. I've read a bit on the internet on putting shims above the rear springs and there were also some machined inserts (30mm) for the fronts. I was also considering go-westy front springs with 2" but sort of ditched it, as I've read somewhere, that they are too hard for tintops. I have access to a lathe, so might make the front inserts out of nylon. Suggestions?


I've also sourced some VW 15 inch rims, that I'll be putting Firestone Destinations AT 205/75R15 on, which should lift the van for another approx 10mm. A question here would be: small ball nuts for 14mm studs...are they available anywhere in Australia or is order from gowesty, van-cafe, t3techniqueetc. the only option? 


I need to but new accelerator cable as well and new bushings for power steering rack attachment, so might join the order. Please suggest, which shop is the way to go.


And to the last, a bit more technical question. 

On a few occasions (since December, that I bought syncro) driving fast on very deep sand, the clutch pedal went hard and the clutch wouldn't disengage. The first time it happened I had to drive home on fully engaged clutch. Next day I took the van to the clutch specialist and when he wanted to look at it, it was working normally out of the sudden. It happened on a few other occasions (always while driving rough on the sand). Last time it happened the symptoms disappeared as soon as I opened the hood to try and open the bleeder on the slave to see if that makes the pedal soft.

I tried to find ideas on the internet and similar is mentioned only once on samba, when someone was saying, that the mechanic put the clutch release plate (bearing???) upside down, so it can interfere with some springs and cause it to jam.

This clutch was serviced (new clutch kit, replaced fork with a good second hand one) last September (car travelled 10k km since then) and when this happened for the first time, it was only about 2500km since that service.


Any suggestions to the above highly appreciated.


Cheers

Beau

 


 

2
Nice rig,

My van has been lifted but I still got trapped a couple of times when the wheels dig in.

Reverse is a good friend and so is momentum and low tyre pressures to get out and through.

Lifting can be done with spacers - I have them in the rear and coil overs on the front which allows me 2 inches of adjustment.

What engine do you have in your syncro?

Cheers,

Skot

On 3/05/2017 10:02 AM, beau.sagadin@yahoo.com [Syncro_T3_Australia] wrote:

Hey guys.


We've been on the Fraser during last easter holidays. We had a great time and it was also a good test for our syncro.

We got bogged a couple of times on the deep wheel tracks because of lack of ground clearance of the van. No worries, as we were travelling in a group so got it out with a gentle pull with a snatch - nothing too aggressive. Anyway, we've decided to do something about it. At the moment, I have 200mm clearance at the lowest point (bash brackets under the engine) and about 220mm everywhere else. I've read a bit on the internet on putting shims above the rear springs and there were also some machined inserts (30mm) for the fronts. I was also considering go-westy front springs with 2" but sort of ditched it, as I've read somewhere, that they are too hard for tintops. I have access to a lathe, so might make the front inserts out of nylon. Suggestions?

< span>

I've also sourced some VW 15 inch rims, that I'll be putting Firestone Destinations AT 205/75R15 on, which should lift the van for another approx 10mm. A question here would be: small ball nuts for 14mm studs...are they available anywhere in Australia or is order from gowesty, van-cafe, t3techniqueetc. the only option?


I need to but new accelerator cable as well and new bushings for power steering rack attachment, so might join the order. Please suggest, which shop is the way to go.


And to the last, a bit more technical question.

On a few occasions (since December, that I bought syncro) driving fast on very deep sand, the clutch pedal went hard and the clutch wouldn't disengage. The first time it happened I had to drive home on fully engaged clutch. Next day I took the van to the clutch specialist and when he wanted to look at it, it was working normally out of the sudden. It happened on a few other occasions (always while driving rough on the sand). Last time it happened the symptoms disappeared as soon as I opened the hood to try and open the bleeder on the slave to see if that makes the pedal soft.

I tried to find ideas on the internet and similar is mentioned only once on samba, when someone was saying, that the mechanic put the clutch release plate (bearing???) upside down, so it can interfere with some springs and cause it to jam.

This clutch was serviced (new clutch kit, replaced fork with a good second hand one) last September (car travelled 10k km since then) and when this happened for the first time, it was only about 2500km since that service.


Any suggestions to the above highly appreciated.


Cheers

Beau



--
Best regards, Scott Pitcher SPB Consulting
3
Hey Skot.

Yes, it is nice. I love it beyond words can explain :) If that makes any sense :)

I've driven everywhere around inskip, rainbow beach, double island point etc. A few times passing bogged cruisers and patrols. Never got bogged before. Tyres down, proper momentum etc. etc.Never any issues.  On Fraser though there were a couple of tracks, that had long incline and deep tracks (you know the fancy big muddies riggs destroying the sandy tracks), that even going as fast as possible didn't get me over. It went plowing with belly for about 15-20 meters , but slowing me down so eventually it ran out of power. I stopped, tried reversing and again and basically stopped at the same point. Mate with Pajero had only 3cm more ground clearance and didn't touch the sand between wheel tracks much, so got thru easy.

Anyway, 50mm spacers at the back is sorted. I need to find some good nylon or similar high density plastic material to machine front coils inserts.
I just got 4 new Firestone Destinations fitted today to new rims. All I need now is to source small ball lug nuts.
At the moment, I have Cooper Discoverer 215/75R14, which are good, but the threads are coming to an end and couldn't really soruce any more A/T tyres for 14 inch rims...hence the 15inch rims upgrade.
 
At the back is original 2.1l engine, fitted with 2.4l go-westy upgrade. No issues so far apart from the completely stuffed starter motor, that I cleaned and re soldered new brushes in last weekend. Also added extra cable from alternator to starter and extra earth from starter bolt to chassis. It starts like new now :)

In the near future I need to look into alternator as well, as it is giving me only about 13.85V and when I turn on headlights and when the radiator comes on, it falls down to 13.3V and does not recover as long as those are turned on.

P.S.: any ideas on clutch brainer? :)

Cheers
Beau
4
Hi Beau,

Looks like you had a ball.

Is it the camera, my dodgy eyes or your side windows are non-standard?

I had a similar issue on Moreton Island but only going across the track through the bottom end of the beach. It is a narrow track that winds across the bottom of the island.

When we went it was at the end of a busy summer school holidays after a prolonged drought and the sand was very soft and churned up.

There was a 300m length of track that was like quick sand and after rounding a sharp blind bend slowly so I didn't crash into oncoming traffic, I only got about half way across before I ran out of puff. Reversed back and had another go and got about 200m through then reversed back again and got through. That was fun - especially with the wife complaining that we should turn around - Ha! Cant do that :)

Sand driving is fun!

Mine is fairly high now and running 235 x 75 x 15 tyres - see photo

Cheers,

Skot

On 3/05/2017 8:06 PM, beau.sagadin@yahoo.com [Syncro_T3_Australia] wrote:

Hey Skot.


Yes, it is nice. I love it beyond words can explain :) If that makes any sense :)

I've driven everywhere around inskip, rainbow beach, double island point etc. A few times passing bogged cruisers and patrols. Never got bogged before. Tyres down, proper momentum etc. etc.Never any issues. On Fraser though there were a couple of tracks, that had long incline and deep tracks (you know the fancy big muddies riggs destroying the sandy tracks), that even going as fast as possible didn't get me over. It went plowing with belly for about 15-20 meters , but slowing me down so eventually it ran out of power. I stopped, tried reversing and again and basically stopped at the same point. Mate with Pajero had only 3cm more ground clearance and didn't touch the sand between wheel tracks much, so got thru easy.

Anyway, 50mm spacers at the back is sorted. I need to find some good nylon or similar high density plastic material to machine front coils inserts.
I just got 4 new Firestone Destinations fitted today to new rims. All I need now is to source small ball lug nuts.
At the moment, I have Cooper Discoverer 215/75R14, which are good, but the threads are coming to an end and couldn't really soruce any more A/T tyres for 14 inch rims...hence the 15inch rims upgrade.
At the back is original 2.1l engine, fitted with 2.4l go-westy upgrade. No issues so far apart from the completely stuffed starter motor, that I cleaned and re soldered new brushes in last weekend. Also added extra cable from alternator to starter and extra earth from starter bolt to chassis. It starts like new now :)

In the near future I need to look into alternator as well, as it is giving me only about 13.85V and when I turn on headlights and when the radiator comes on, it falls down to 13.3V and does not recover as long as those are t urned on.

P.S.: any ideas on clutch brainer? :)

Cheers
Beau

--
Best regards, Scott Pitcher SPB Consulting
5
Hi Beau,     It's always great to see a Syncro out being used in anger. As far as the front spacers go I would be machining them out of aluminium. The lip is there to locate the spring and I think nylon would not hold up to this stress long term.
     Re the rims, are you using Tiguan rims? If so yes the best source is T3 technique for the small ball nuts. Chris also has the steering rack bushes. There is a super easy way to replace those bushes if you don't already know.
    The clutch is an odd one. If you are talking about the clutch not being able to be depressed, while it could be a lot of things, I would be wondering if the mechanic replaced the thrust bearing support sleeve? A new thrust bear on an old sleeve will often cause issues. Also was the bell housing sealed? If sand is getting in it will cause havoc. Gregor


From: "beau.sagadin@yahoo.com [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com>
To: Syncro_T3_Australia@yahoogroups.com
Sent: Wednesday, 3 May 2017, 20:06
Subject: Re: [Syncro_T3_Australia] Syncro on easter - afterthoughts :) [4 Attachments]

 
Hey Skot.

Yes, it is nice. I love it beyond words can explain :) If that makes any sense :)

I've driven everywhere around inskip, rainbow beach, double island point etc. A few times passing bogged cruisers and patrols. Never got bogged before. Tyres down, proper momentum etc. etc.Never any issues.  On Fraser though there were a couple of tracks, that had long incline and deep tracks (you know the fancy big muddies riggs destroying the sandy tracks), that even going as fast as possible didn't get me over. It went plowing with belly for about 15-20 meters , but slowing me down so eventually it ran out of power. I stopped, tried reversing and again and basically stopped at the same point. Mate with Pajero had only 3cm more ground clearance and didn't touch the sand between wheel tracks much, so got thru easy.

Anyway, 50mm spacers at the back is sorted. I need to find some good nylon or similar high density plastic material to machine front coils inserts.
I just got 4 new Firestone Destinations fitted today to new rims. All I need now is to source small ball lug nuts.
At the moment, I have Cooper Discoverer 215/75R14, which are good, but the threads are coming to an end and couldn't really soruce any more A/T tyres for 14 inch rims...hence the 15inch rims upgrade.
 
At the back is original 2.1l engine, fitted with 2.4l go-westy upgrade. No issues so far apart from the completely stuffed starter motor, that I cleaned and re soldered new brushes in last weekend. Also added extra cable from alternator to starter and extra earth from starter bolt to chassis. It starts like new now :)

In the near future I need to look into alternator as well, as it is giving me only about 13.85V and when I turn on headlights and when the radiator comes on, it falls down to 13.3V and does not recover as long as those are turned on.

P.S.: any ideas on clutch brainer? :)

Cheers
Beau


6
Hey Greg.

Thanks for your comment.

Just ordered nuts and bushes from T3technique. Hope they get here soon.

Regarding clutch, it was done last Spetember at VolksWerke in Greensborough (Melbourne)..
It says: "Supplied and fitted new SachsGerman clutch kit. Replace worn sach slave cylinder and very good condition S/H clutch fork. Bleed hydraulics and test drive." on the invoice. 

The clutch seems sealed.

To explain again, what happens, when this occurs. The pedal becomes very hard, but can be pressed all the way down - but that does not disengage the clutch. So if the engine is turned off and I have it in gear, clutch depressed and crank the starter motor, the van starts to move... Looking at the slave, pressing clutch moves the lever sort of normally, but you can see, there is much greater force, as the bracket, holding the slave is moving a bit.

Funny is, that it always sorted itself out, so was never able to properly follow up. Even the clutch specialist said, that he doesn't want to diagnose a perfectly working clutch :)

P.S.: Skot, your eyes are correct - the van is converted from transporter to Caravelle with full sized rockenroll bed :)

Best regards
Beau


---In Syncro_T3_Australia@yahoogroups.com, <gregespo73@...> wrote :

Hi Beau,     It's always great to see a Syncro out being used in anger. As far as the front spacers go I would be machining them out of aluminium. The lip is there to locate the spring and I think nylon would not hold up to this stress long term.
     Re the rims, are you using Tiguan rims? If so yes the best source is T3 technique for the small ball nuts. Chris also has the steering rack bushes. There is a super easy way to replace those bushes if you don't already know.
    The clutch is an odd one. If you are talking about the clutch not being able to be depressed, while it could be a lot of things, I would be wondering if the mechanic replaced the thrust bearing support sleeve? A new thrust bear on an old sleeve will often cause issues. Also was the bell housing sealed? If sand is getting in it will cause havoc. Gregor


From: "beau.sagadin@... [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com>
To: Syncro_T3_Australia@yahoogroups.com
Sent: Wednesday, 3 May 2017, 20:06
Subject: Re: [Syncro_T3_Australia] Syncro on easter - afterthoughts :) [4 Attachments]

 
Hey Skot.

Yes, it is nice. I love it beyond words can explain :) If that makes any sense :)

I've driven everywhere around inskip, rainbow beach, double island point etc. A few times passing bogged cruisers and patrols. Never got bogged before. Tyres down, proper momentum etc. etc.Never any issues.  On Fraser though there were a couple of tracks, that had long incline and deep tracks (you know the fancy big muddies riggs destroying the sandy tracks), that even going as fast as possible didn't get me over. It went plowing with belly for about 15-20 meters , but slowing me down so eventually it ran out of power. I stopped, tried reversing and again and basically stopped at the same point. Mate with Pajero had only 3cm more ground clearance and didn't touch the sand between wheel tracks much, so got thru easy.

Anyway, 50mm spacers at the back is sorted. I need to find some good nylon or similar high density plastic material to machine front coils inserts.
I just got 4 new Firestone Destinations fitted today to new rims. All I need now is to source small ball lug nuts.
At the moment, I have Cooper Discoverer 215/75R14, which are good, but the threads are coming to an end and couldn't really soruce any more A/T tyres for 14 inch rims...hence the 15inch rims upgrade.
 
At the back is original 2.1l engine, fitted with 2.4l go-westy upgrade. No issues so far apart from the completely stuffed starter motor, that I cleaned and re soldered new brushes in last weekend. Also added extra cable from alternator to starter and extra earth from starter bolt to chassis. It starts like new now :)

In the near future I need to look into alternator as well, as it is giving me only about 13.85V and when I turn on headlights and when the radiator comes on, it falls down to 13.3V and does not recover as long as those are turned on.

P.S.: any ideas on clutch brainer? :)

Cheers
Beau


7
Beau,

Have you checked the top of your clutch pedal?

The hole the pin goes through wears and elongates and in some cases pushes through.

Maybe this happens to you on occasion.

If you can get your head under there to have a look you may have your answer.

My 2wd one wore very badly and nearly to that situation.

To fix you need to remove the clutch pedal, weld up the hole and drill a new hole.

A big job.

Cheers,

Skot

On 7/05/2017 9:10 PM, beau.sagadin@yahoo.com [Syncro_T3_Australia] wrote:

Hey Greg.


Thanks for your comment.

Just ordered nuts and bushes from T3technique. Hope they get here soon.

Regarding clutch, it was done last Spetember at VolksWerke in Greensborough (Melbourne)..
It says: "Supplied and fitted new SachsGerman clutch kit. Replace worn sach slave cylinder and very good condition S/H clutch fork. Bleed hydraulics and test drive." on the invoice.

The clutch seems sealed.

To explain again, what happens, when this occurs. The pedal becomes very hard, but can be pressed all the way down - but that does not disengage the clutch. So if the engine is turned off and I have it in gear, clutch depressed and crank the starter motor, the van starts to move... Looking at the slave, pressing clutch moves the lever sort of normally, but you can see, there is much greater force, as the bracket, holding the slave is mo ving a bit.

Funny is, that it always sorted itself out, so was never able to properly follow up. Even the clutch specialist said, that he doesn't want to diagnose a perfectly working clutch :)

P.S.: Skot, your eyes are correct - the van is converted from transporter to Caravelle with full sized rockenroll bed :)

Best regards
Beau


---In Syncro_T3_Australia@yahoogroups.com, <gregespo73@...> wrote :

Hi Beau, It's always great to see a Syncro out being used in anger. As far as the front spacers go I would be machining them out of aluminium. The lip is there to locate the spring and I think nylon would not hold up to this stress long term.
Re the rims, are you using Tiguan rims? If so yes the best source is T3 technique for the small ball nuts. Chris also has the steering rack bushes. There is a super easy way to replace those bushes if you don't already know.
The clutch is an odd one. If you are talking about the clutch not being able to be depressed, while it could be a lot of things, I would be wondering if the mechanic replaced the thrust bearing support sleeve? A new thrust bear on an old sleeve will often cause issues. Also was the bell housing sealed? If sand is getting in it will cause havoc. Gregor


From: "beau.sagadin@... [Syncro_T3_Australia]" <Syncro_T3_Australia@yahoogroups.com>
To: Syncro_T3_Australia@yahoogroups.com
Sent: Wednesday, 3 May 2017, 20:06
Subject: Re: [Syncro_ T3_Australia] Syncro on easter - afterthoughts :) [4 Attachments]

Hey Skot.

Yes, it is nice. I love it beyond words can explain :) If that makes any sense :)

I've driven everywhere around inskip, rainbow beach, double island point etc. A few times passing bogged cruisers and patrols. Never got bogged before. Tyres down, proper momentum etc. etc.Never any issues. On Fraser though there were a couple of tracks, that had long incline and deep tracks (you know the fancy big muddies riggs destroying the sandy tracks), that even going as fast as possible didn't get me over. It went plowing with belly for about 15-20 meters , but slowing me down so eventually it ran out of power. I stopped, tried reversing and again and basically stopped at the same point. Mate with Pajero had only 3cm more ground clearance and didn't touch the sand between wheel tracks much, so got thru easy.

Anyway, 50mm spacers at the back is sorted. I need to find some good nylon or similar high density plastic material to machine front coils inserts.
I just got 4 new Firestone Destinations fitted today to new rims. All I need now is to source small ball lug nuts.
At the moment, I have Cooper Discoverer 215/75R14, which are good, but the threads are coming to an end and couldn't really soruce any more A/T tyres for 14 inch rims...hence the 15inch rims upgrade.
At the back is original 2.1l engine, fitted with 2.4l go-westy upgrade. No issues so far apart from the completely stuffed starter motor, that I cleaned and re soldered new brushes in last weekend. Also added extra cable from alternator to starter and extra earth from starter bolt to chassis. It starts like new now :)

In the near future I need to look into alternator as well, as it is giving me only about 13.85V and when I turn on headlights and when the radiator comes on, it falls down to 13.3V and does not recover as long as those are turned on.

P.S.: any ideas on clutch brainer? :)

Cheers
Beau



--
Best regards, Scott Pitcher SPB Consulting
8
Hey Skot.

Yes, I've checked that too. It is a bit elongated (let's say about 1mm bigger radius in that direction), so there is about 2-3mm play on the pedal (you can press the pedal for about 2-3mm before the plunger pin actually starts to move), but I highly doubt, that would cause the symptoms, explained before.
I suppose the clutch will have to come off eventually and triple check the conditions of bearings, fork, etc in there.
Thanks for the tip though. 

Cheers
Beau