Copyright 1997 Bob Storm
OK, where were we at the end of Part 1? Oh yeah, after 5 weeks, and more parts money than I knew I had, we got this '85 to start and idle. Time for a test drive. Troy--take it around the block while I start cleaning up tools.
OOPS! Where did that stream of oil come from? Here he comes now; I hope there is still some oil in it! Ah, here's the problem. After reinstalling the upper manifold, the dipstick tube mounting bracket no longer has the tube in the block. Man, what a mess.
The idle is still rough, but it drives OK, so sure you can drive it to school. How did it go today? The doors won't lock? I know it's cool but not enough to ice up. We can make a door panel puller like the one in the factory repair manual here, and see what is going on. Let me disconnect the electric lock. There, at least we can lock it now. This manual override on the locking solenoid just will not move. There's another pair of items for the shopping list.
Troy, I agree that the idle is rough and erratic. Let's try that new idle air bypass again. Good. Even though the idle is still rough, at least it's constant--no more "automatic" idle increases to 2200 RPM. Guess it was time.
Linda, Troy suggested that I ask you about the trip to get his senior pictures taken. Why are you shaking? He forgot his trumpet for a prop? So? Oh, you came home to get it. He told you to buckle up and hang on. Well, did you? From studio to the house, 15 miles across McNeil, Parmer, and Brushy Creek Road (narrow and winding) in 13 minutes. Hey, you're shaking again, must have been some ride! Guess its a good thing you had a factory race car to make a trip like that in such a short time.
Wow! On the road now for 4 months without a uh oh, now what? It won't go into gear? Here we go again. Almost seems like a throwout bearing, but not quite. Get out the ramps and jack stands, we're goin' in.
Let's only do this once. Take the drive shaft, get it balanced and straightened if necessary, and new U-joints installed. Differential feels a little rough, but I'm not sure how it's supposed to feel. It doesn't have to come out so cross your fingers.
Now for the tranny. I sure hope this new electric impact wrench performs as long as the loan to pay for it, but I can't imagine getting this car apart without one. That dipstick tube has to come out to get to that bolt. Gotta remember to put it back in when were done.
I sure do wish I had ordered that plastic transmission shaft plug. This old gear lube tastes horrible! Finally out, in spite of the mess. Hey, does that guy at work still have the World Class T5 kit? Might as well freshen the tranny while it's out.
OK, release the clutch cable and let's get down to the source of the problem. By the way, remember Jim Whelan's story about replacing the clutch cable? Let's go ahead and order one while were here. Be careful, at this angle that pressure plate may feel heavy. Great, now let's get the flywheel off. The way the engine wants to turn, I guess this impact wrench has just about paid for itself already.
OK, let's see what we've got besides a lot of old dirty grease. Throwout bearing doesn't look near as bad as I expected. Maybe that wasn't the problem. We sure did get lucky on this one; the clutch plate rivets would have been into the flywheel in another month or two. The flywheel can be resurfaced and work just fine, but these ring gear teeth don't look so good. Maybe we can get the ring gear replaced. Not replaceable? How much is a new flywheel? Well, those teeth don't look so bad after all. I'll bet they'll debur nicely with a Dremel stone and the rattail file from my chain saw sharpener. Just swing that magnifying light over here so I can see. There now, that looks pretty good. One down and, good gosh!! only 131 more to go. Oh, my aching back! But just think how much money I saved per tooth. Yep, for trivia, bar bets, or SVO gatherings, there's 132 teeth on the flywheel ring gear.
Time to order some parts. Hello, is this Motion Dynamics? Great! Jim, I need a clutch disk, pressure plate, throwout bearing, bell housing dust boot, and a recommendation for a T5 rebuilder. You also rebuild! I'll bring the tranny and kit right over.
By the way, I found a couple of small pieces of metal on the floor. About 3/8" long, round, kinda like, what's that? A pilot bearing? No, there's no bearing in the back of the crankshaft. Do you suppose? Better order one of those too.
Well, while the driveshaft, flywheel, and transmission are being worked on, let's put the new clutch cable in. Yes, it's a bit of a hassle, but everything is in place except for the aluminum quadrant that goes under the dash. Troy, you're young enough to bend like that, would you please? Just be careful while you are upside down under there. Don't drop that. @#%* oops, too late. But that's one of the prettier black eyes I've seen lately. How about some goggles next time?
How in the world do you get the remains of the pilot bearing out? Jim? The puller costs how much? Could I just rent one for a third of that plus a six pack of Shiner Bock? What a difference the right tool makes! Five minutes vs. 2 days.
I ordered a clutch alignment tool but with the input shaft from that box of junk that came with the T5 kit, we won't need to use it, and this will work better. Let's just try the new pilot bearing on this shaft before installing it. What? Not even close? What gives? The bearing OD seems about right, but the ID is way off.
Troy, take this bearing over to Jim's shop and try it on our transmission. Hello. OK, the good news first--the bearing is a perfect fit. Great! Apparently, there is a difference in the input shaft dimensions between the 4 cylinder and 8 cylinder versions. Now, the bad news. The Grand Am won't start. Good thing the mini van's running this weekend. I'll be over in a few minutes. Yes, I'll pick up a battery on the way.
Yes, Jim, what can I do for You? You're kidding! You're not kidding. This "kit" has extra 3-4 synchros but no 1-2 synchros? And the 3rd gear caged bearing is wrong. So much for a good deal. Go ahead and order them. How much? That, plus the price for the "kit" comes out to about the list price of the kit had we ordered it. Oh well, gotta have 'em. By the way, what about gear lube? Auto transmission fluid, huh? By the smell, I know that's not what was in there!
OK, that's everything back together but the starter motor. Hey Dad, are starter motors supposed to rattle? And is this little gear on the end supposed to squeak when you turn it? I didn't think so. Uh, I gotta go clean up for work. Can you go after the new one? Thanks, Dad, put it on my "owe you another one" list. You want to drive the mini van or Grand Am? Don't forget the mobile phone, just in case.
I don't see any extra parts laying around. Man, I can't wait to feel this new tranny shift! Who's going to get the test run? Flip ya, Troy...just kidding. I'll stay here in case we need to call a wrecker. OK, remember the break in instructions and good luck.
From your smile, I gather that everything works. Too bad you're not taking it to college with you but I promise I'll exercise her...uh, I mean I'll take good care of her for you.
Two weeks later...you know after driving the SVO, the Grand Am doesn't seem to handle as good as I remember. Thanks for leaving her here. No problem, Dad, I gotta go. I know I just got home, Mom, but my baby here needs some attention and a work out...catch ya later.
The squeal of tires and a cloud of dust...Now, if only I can find where that oil smell is coming from...
Part III: Menagerie a Troisor! How Charming is the Third Time?