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Author Topic: Tapping/Knocking Noise  (Read 29376 times)
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Dilambdaman
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« Reply #30 on: 10 June, 2013, 06:52:34 AM »

Hi Andy,

I truly do feel for you having suffered a similar problem with the Dilambda a couple of years ago. What I will say is that the relief and pleasure you experience when you finally solve the problem is immense and so satisfying. Keep at it.

Robin.
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Robin Lacey 3222

1932 Dilambda
1969 Fulvia S1 1.6HF Fanalone
the.cern
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« Reply #31 on: 19 May, 2014, 08:50:04 PM »

So, I made a poor decision on 5th June last year, it was not the doughnuts, even though they were knackered.

By the 7th I had the car up on blocks and stands, the prop off and engine bay ready to remove the gearbox. However, it was not until the 24th I removed the gearbox only to find that the exchange box was from a LHD car. A quick call to Don for advice ... it is simple, swap the selector mechanism and the clutch lever for that on my gearbox, but do not lose the springs in the selectors (I didn't). Now it was time to install the replacement gearbox. Next day we set to, a lot of huffing and puffing followed by quite a few expletives when we discovered the loaned series 1 box does not fit a series 2 car. The latter has 2 additional securing studs which of course prevent a series 1 unit sliding into place. So, the loan 'box was dragged out and the gear selector mechanism and clutch lever were swapped back and my 'box readied to go to a transmission specialist for checking. In due course the 'box was checked and on 25th July, having been pronounced as fit for purpose the 'box was collected from the transmission specialist and a new friction plate ordered from Don which came 2 days later, what a service!!

Jim said he would be up to help and Tim (lancialulu) also offered his assistance. However, I had a couple of health scares and Lynn's treatment became significantly more onerous, so unfortunately that is how things remained until two days ago. I suddenly got fired up and decided to, very carefully, have a go at doing the job on my own. On Friday I recovered all the bits from different parts of the garage, installed the clutch in the bellhousing and located the support cradle for the box. Saturday was crunch day, the 'box was installed in the cradle on the trolley jack and, after 3 abortive attempts I managed to get it under the car. If only I had blocked it up another 20mm!!! There was only one way it could be slid in, pushing a trolley jack, loaded with a gearbox sideways when lying down is not easy!! Raising the was of course easy, as was applying the correct tilt thanks to Jim's cradle. However, it hit the transmission tunnel before it was high enough to be moved forward onto the studs. When Jim and I hit this problem with the loan box, I resorted to levering the top of the engine, at the front, backwards, thus lowering the rear  of the engine whilst Jim manoeuvred the box towards the studs. This time on my own I had to think again, then I suddenly recalled Chugga's 'how to remove an Appia gearbox' list which I had looked through rather than read. However, jack under the front of the engine had registered, just. I re-read the post and all was clear. Another jack, on a slight ramp to try to get a lift perpendicular to the bottom of the sump, with a timber spacer to protect the sump and lo and behold, down went the back of the engine exactly as required. I could not believe it when, after a little twisting and tugging and pushing the 'box suddenly slid forward onto the studs. I really could not believe it. I quickly bolted it up before it could slip off again!!! I then jacked up the rear of the box and fitted the gearbox rear support bolt.

That is how it is now, sitting ignored in the garage while I am on holiday in a beautiful villa some 30 mls north of Perugia.

To be continued ....

                          Andy
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Parisien
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« Reply #32 on: 19 May, 2014, 09:00:49 PM »

...always believe Andy.........

Enjoy your holiday........


P
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Frank Gallagher
DavidLaver
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« Reply #33 on: 20 May, 2014, 09:05:35 AM »


Power of the forum eh?  ....and of determination and resolve and patience and planning and being organised enough not to loose the bits and orderly enough to have the tools to hand and keeping your temper with it.

It was certainly the weather to be lying under a car this weekend (I couldn't resist on Sunday - fuel tank and pump out of the Strada) and fingers crossed all is well and if not you know you've got a good box and clutch in the same way you know you've got good engine mounts and as you work through the car chasing "the fault" what you leave behind is better and stronger and will give peace of mind when you drive me down to Italy in it (stopping at Simon's on the way) to pick up one of the mythical Flavia Jolly vans at 2000 euro (see Viva Lancia).

Enjoy your break!!

David
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David Laver, Lewisham.
the.cern
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« Reply #34 on: 20 May, 2014, 03:27:27 PM »

David, power of the forum indeed!! I definitely would not have got the gearbox back in without the forum and Chugga's contribution. Long may it continue.

                                         Andy
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simonandjuliet
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« Reply #35 on: 20 May, 2014, 05:13:02 PM »

Certainly hope that you have cured the problem ! Looking forward to hearing the news ....
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S1 Aprilia Cabrio, S2 Aprilia, S1 Promiscuo,S2 camioncino, S2 furgoncino, , R4 Sinpar, R4 Rodeo, R60 Tractor,R60 S, Moto Guzzi Ercole, Disco 3, Mini ALL4 JCW, Moto Guzzi Cardellino 73,Fulvia Berlina GT, Fulvia Rallye S, Royal Enfield Himalayan
the.cern
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« Reply #36 on: 28 May, 2014, 08:40:53 PM »

A little while yet until I can find out if I have sorted the problem I regret Simon ....

I had a fantastic holiday, spoilt rotten by ex pats who are living the dream, but working bloody hard at it. The lady of the house was a brilliant cook (runs Italian cookery courses) whilst her husband had planted a vineyard and an olive grove and made his own wine and olive oil. I am not a fan of the latter, but the former was superb and sampled, in quantity, every evening.

Anyway I digress ..... it was back to reality late on Sunday evening after a two and a half hour delay at Perugia airport due to bad weather!!!! Monday was recovery day and catch up with the family. Tuesday was rolling around on the garage floor day!!! First it was necessary to bolt the clutch assembly to the flywheel. The two seemed locked together and I could not turn one relative to the other to get the bolt holes to line up. So, I released the bellhousing nuts, but the unit was still tight on the gearbox mounting bolt and would not move. I removed the mounting bolt, but wanted to secure the tail of the gearbox by threading a rope through the silentblock and tying it to the transmission tunnel. To assist in this I removed the rubber bushed supports each side, a bad move as they are a beast to replace as a one man job. Anyway, releasing the gearbox allowed the clutch to move relative to the flywheel and I got the 8 bolts in and tightened up. Then it just remained to tighten the bellhousing nuts, get that expletive deleted rear mounting back in and I was back to where I was before I went on holiday!!!   The top hose went on and I called it a day.

Today it was fit the gearchange linkage, tricky, but manageable, refit the clutch linkage, easy and refit the exhaust. The latter should not be that difficult. However, my (stainless) exhaust has a bush which locates between the pipe and the manifold and a copper and 'asbestos' circular gasket. Plenty of gun gum type goo and bolt it up, very poor access and difficult to get to the nuts, but managed it. Then today's cock-up came to light. In all the faffing around to get the down pipe flange located on the manifold studs, the gasket had fallen off and, being covered in goo it just dropped a few inches and then stuck itself to the bellhousing. I only realised this as I was extricating myself from under the car thinking I had successfully secured the down pipe when the bally thing unglued itself and dropped onto the floor under my nose!!!! Needless to say the air was blue!!!!!! I unbolted the downpipe, applied more goo to the bush and the gasket and bolted it back up, at least it only took two attempts, not the usual three!!!!!

So, that is where we are at the moment ....... only the plugs, air cleaner and other little bits to go back, then new oil in the gearbox and fill the cooling system and we might even be ready to give it a go ........

Any recommendations for type of oil for the gearbox, I am tending towards SAE30?

                                                        Andy
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DavidLaver
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« Reply #37 on: 28 May, 2014, 08:44:10 PM »


"thinking I had successfully secured the down pipe when the bally thing unglued itself and dropped onto the floor under my nose".

You couldn't script it.

I guess you could now become an authorised Appia exhaust and clutch fitter.

David
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David Laver, Lewisham.
simonandjuliet
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« Reply #38 on: 29 May, 2014, 06:09:54 AM »

Thanks for the warning - I have 2 of these coming up ! Do you think that you could fit the exhaust downpipe before refitting the engine/box assembly ?

Re oil, not sure but what does it say in the handbook ?

Fingers crossed that the rest goes smoothly 
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S1 Aprilia Cabrio, S2 Aprilia, S1 Promiscuo,S2 camioncino, S2 furgoncino, , R4 Sinpar, R4 Rodeo, R60 Tractor,R60 S, Moto Guzzi Ercole, Disco 3, Mini ALL4 JCW, Moto Guzzi Cardellino 73,Fulvia Berlina GT, Fulvia Rallye S, Royal Enfield Himalayan
simonandjuliet
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« Reply #39 on: 29 May, 2014, 07:32:17 AM »

Handbook recommends EP 90 - Mobilube GX 90 or ESSO XP Compound EP 90 to be exact !
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S1 Aprilia Cabrio, S2 Aprilia, S1 Promiscuo,S2 camioncino, S2 furgoncino, , R4 Sinpar, R4 Rodeo, R60 Tractor,R60 S, Moto Guzzi Ercole, Disco 3, Mini ALL4 JCW, Moto Guzzi Cardellino 73,Fulvia Berlina GT, Fulvia Rallye S, Royal Enfield Himalayan
the.cern
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« Reply #40 on: 29 May, 2014, 07:38:31 AM »

Thanks for the warning - I have 2 of these coming up ! Do you think that you could fit the exhaust downpipe before refitting the engine/box assembly ?

Re oil, not sure but what does it say in the handbook ?

Fingers crossed that the rest goes smoothly 


Simon, re the downpipe, mine is a non standard exhaust and the downpipe is long, it extends to nominally the rear footwell, so would be difficult to manoeuvre into place unless you have the car on a lift. It was not that difficult to fit with the engine in place, small hands help (I took off the gloves I normally wear), it was having to do it twice ......

Re oil, the handbook recommends 'Mobilube GX90' or 'Esso XP Compound EP90'. However, there is thread elsewhere on the Forum which discusses lubricants and that is suggesting a lighter oil seems to give easier gear changes, absorb less power and has no downside!!  Also, I checked on the 'Morris of Shrewsbury' website.They consider their Golden Film SAE30 is 'suitable for use in naturally aspirated four stroke petrol and diesel engines and classic gearbox designs'. The latter is not very specific, but, when considered with the Forum thread seems to give weight to the argument for the use of SAE30.

Does anyone else have experience or thoughts on this?

                                     Andy
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lancialulu
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« Reply #41 on: 29 May, 2014, 07:47:38 AM »

Re oil I thought that was for an Augusta or Aprilia but then my memory is playing tricks on me from time to time. like forgetting to bring the Delta twin cam timing to France to change the belt on our 1600. bought everything else..
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Its not the winning but taking part! or is it taking apart?
1955 Aurelia B12
1967 Flavia Vignale iniezione
1967 Fulvia 1.3HFR
1972 Fulvia 1600HF
1972 Fulvia 1600HF
1972 1600 Fulvia Sport
1979 2500 Gamma Coupe
1988 Delta 1.6GTi
1998 Zeta
DavidLaver
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« Reply #42 on: 29 May, 2014, 08:40:26 AM »

"It was not that difficult to fit with the engine in place, small hands help"


If ever there was a half time activity for the grandchildren surely an Appia exhaust fitting was it...

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David Laver, Lewisham.
simonandjuliet
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« Reply #43 on: 29 May, 2014, 09:36:05 AM »

Unfortunately I do not fall into the small hands category, perhaps Juliet can do it - it's her car after all ........

(I'll get a kicking for that one !)
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S1 Aprilia Cabrio, S2 Aprilia, S1 Promiscuo,S2 camioncino, S2 furgoncino, , R4 Sinpar, R4 Rodeo, R60 Tractor,R60 S, Moto Guzzi Ercole, Disco 3, Mini ALL4 JCW, Moto Guzzi Cardellino 73,Fulvia Berlina GT, Fulvia Rallye S, Royal Enfield Himalayan
the.cern
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« Reply #44 on: 29 May, 2014, 02:30:02 PM »

I count myself lucky when retribution is merely a kicking.

Lynn is on crutches at the moment so even I can outrun her, but I do have to remember the extended reach that they give her ....

                                    Andy
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