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Christ · 06-23-2010, 02:08 AM

Few setbacks and problems with Gerald recently:

Brakes have been intermittently malfunctioning, sticking, or just not working at all. Finally "gave up" on me the other day... I took the opportunity to change the aged (read: ugly and corroded) master cylinder, and both front calipers with clean, nearly new units sourced from the local recycler for $50 even.

While I was there, I also managed to score one of those LUND grille block screen things that you cut to fit your grille. I got those for free... all of the panels except the one you can't cover for your hood opening, including the plastic brackets that hold them in. I'm going to paint them and install them later.

Changing the calipers and M/C didn't actually fix the brake problem. I still only get enough pedal to activate one rear brake. I need to check under the dash to make sure there isn't a malfunction at the pedal assembly itself, which is quite possible.

A/C pump pulley is shot... The clutches are gone, and the pulley rides crooked and grinds against a bolt. It heats up, and this, of course, caused the belt to break. Grabbed an OE belt thinking that it was the same for the no A/C configuration, but it wasn't. Ended up with a belt from a 3.3 Caravan, which bypasses the AIR pump as well. Not happy about that, but it got me home.

I notice that in order to remove the PS and A/C, I'm left with no accessories on that side of the engine... where the tensioner is. This won't work. I'll either need bypass pulleys, I'll need to relocate something to still be able to use the tensioner, or build a new tensioner from something else to mount elsewhere on the engine. There may be another way, but I haven't looked closely enough at it, yet. Been focusing on the brakes for the most part.

Almost managed to buy another 4.9L engine for a turbo application for $50 that was a crate motor with less than 500 miles from a fire damaged truck. No damage to the engine, just soot on it and baked paint. Missed it by just a hair, though. I'm still working on another one, however, same price, more miles, and extra accessories.

06-23-2010, 02:08 AM	#125 (permalink)
Christ Moderate your Moderation. Join Date: Nov 2008 Location: Troy, Pa. Posts: 8,919 Pasta - '96 Volkswagen Passat TDi 90 day: 45.22 mpg (US) Thanks: 1,369 Thanked 430 Times in 353 Posts	Few setbacks and problems with Gerald recently: Brakes have been intermittently malfunctioning, sticking, or just not working at all. Finally "gave up" on me the other day... I took the opportunity to change the aged (read: ugly and corroded) master cylinder, and both front calipers with clean, nearly new units sourced from the local recycler for $50 even. While I was there, I also managed to score one of those LUND grille block screen things that you cut to fit your grille. I got those for free... all of the panels except the one you can't cover for your hood opening, including the plastic brackets that hold them in. I'm going to paint them and install them later. Changing the calipers and M/C didn't actually fix the brake problem. I still only get enough pedal to activate one rear brake. I need to check under the dash to make sure there isn't a malfunction at the pedal assembly itself, which is quite possible. A/C pump pulley is shot... The clutches are gone, and the pulley rides crooked and grinds against a bolt. It heats up, and this, of course, caused the belt to break. Grabbed an OE belt thinking that it was the same for the no A/C configuration, but it wasn't. Ended up with a belt from a 3.3 Caravan, which bypasses the AIR pump as well. Not happy about that, but it got me home. I notice that in order to remove the PS and A/C, I'm left with no accessories on that side of the engine... where the tensioner is. This won't work. I'll either need bypass pulleys, I'll need to relocate something to still be able to use the tensioner, or build a new tensioner from something else to mount elsewhere on the engine. There may be another way, but I haven't looked closely enough at it, yet. Been focusing on the brakes for the most part. Almost managed to buy another 4.9L engine for a turbo application for $50 that was a crate motor with less than 500 miles from a fire damaged truck. No damage to the engine, just soot on it and baked paint. Missed it by just a hair, though. I'm still working on another one, however, same price, more miles, and extra accessories. __________________ "¿ʞɐǝɹɟ ɐ ǝɹ,noʎ uǝɥʍ 'ʇı ʇ,usı 'ʎlǝuol s,ʇı"