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 Post subject: Rebuilding the 95
PostPosted: Thu Mar 10, 2011 10:41 pm 
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Joined: Sun Mar 14, 2004 12:49 pm
Posts: 189
Location: Monroe, WA
Decided it was time for a rebuild. It really only needed the trans fixed, clutch, and a couple of issues fixed on the motor. May as well just pull the whole thing and go through it, right?? :) I have a new shop on the property so may as well break it in!

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Malcolm

'95 Metro 1.0 / 5 spd
165,000 miles


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 Post subject: Re: Rebuilding the 95
PostPosted: Thu Mar 10, 2011 10:47 pm 
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Location: Monroe, WA
I stripped most of it down over the last couple days. The engine really only needed a new front seal and a ticking adjuster fixed. The clutch still had lots of life left in it, but just felt weak. The trans wouldn't downshift at all so I was sure it had some syncro problems, but they look ok. Probably just the old oil in it keeping it from working. Oh well, rebuild kits are on the way!

I thought it would be cute to put a 455 piston on top for some of my boating buddies. Too bad we couldn't run them without water. =)

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Malcolm

'95 Metro 1.0 / 5 spd
165,000 miles


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 Post subject: Re: Rebuilding the 95
PostPosted: Sat Mar 12, 2011 12:17 am 
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Location: Monroe, WA
Couple more pics from today...

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Malcolm

'95 Metro 1.0 / 5 spd
165,000 miles


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 Post subject: Re: Rebuilding the 95
PostPosted: Sat Mar 12, 2011 12:31 am 
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Location: Alberta, Canada
Strip the pinion shaft of the trans, you will see what happens to the synchros that prevents the down shift. Its not an oil issue, the engaging(?) slots on them get elongated.

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1995 Swift w/16V 4.39s, 3tech cam, Esteem t-body, Header, needs more.
1995 Gt Mustang "Boss Shinoda" package.
1999 F150 4x4 Supercharged
1967 Mustang 428 auto, never ending expensive project
1993 Civic si h22a, fell in my lap, couldn't resist!


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 Post subject: Re: Rebuilding the 95
PostPosted: Sat Mar 12, 2011 8:03 pm 
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Location: Monroe, WA
Ok, I will do that. Just got this in the mail today!

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Malcolm

'95 Metro 1.0 / 5 spd
165,000 miles


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 Post subject: Re: Rebuilding the 95
PostPosted: Thu Mar 17, 2011 10:39 am 
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Location: Monroe, WA
You were right! The outside slots on the syncros were grooved from twisting in the shift hub! 2nd gear was almost toast too. Lucky I had a spare trans for parts.

I'll try to get a good pic of the syncros today, but for now...

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Malcolm

'95 Metro 1.0 / 5 spd
165,000 miles


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 Post subject: Re: Rebuilding the 95
PostPosted: Thu Mar 17, 2011 9:47 pm 
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Location: Monroe, WA
Ok, here's the bad syncro under a good one...

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And I got a present from the brown truck today!!!

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Malcolm

'95 Metro 1.0 / 5 spd
165,000 miles


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 Post subject: Re: Rebuilding the 95
PostPosted: Sat Mar 26, 2011 12:24 am 
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Location: Monroe, WA
Getting started on the motor now that the trans is done.

Homemade piston loading fixture.

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Worked like a charm!

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Then a crankshaft polish.

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Malcolm

'95 Metro 1.0 / 5 spd
165,000 miles


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 Post subject: Re: Rebuilding the 95
PostPosted: Mon Mar 28, 2011 11:18 pm 
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Location: Monroe, WA
Got the crank and the pistons in. Turns out the hot ticket for cleaning the aluminum is hot water and Tide!!

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Malcolm

'95 Metro 1.0 / 5 spd
165,000 miles


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 Post subject: Re: Rebuilding the 95
PostPosted: Wed Mar 30, 2011 11:57 am 
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Joined: Thu Jun 22, 2006 4:38 pm
Posts: 145
Location: Gloucester, Virginia
Loving the rebuild pics. Thinking I need to rebuild my transmission sometime in the next year due to a "cold" stick downshifting to first before it warms up.
Can I ask where you got your rebuild kits from. Part number?


Last edited by GTDave on Wed Mar 30, 2011 9:19 pm, edited 1 time in total.

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 Post subject: Re: Rebuilding the 95
PostPosted: Wed Mar 30, 2011 11:58 am 
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Joined: Thu Jun 22, 2006 4:38 pm
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Location: Gloucester, Virginia
Nice shop by the way.


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 Post subject: Re: Rebuilding the 95
PostPosted: Thu Mar 31, 2011 11:23 pm 
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Location: Monroe, WA
I got kits on eBay. The trans kit was $172 I think. Don't do like we did and use 2nd gear to stop the gears to find first. Second gear was really worn out and I had to replace it. Not everyone has a spare trans to rob pieces from.

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Malcolm

'95 Metro 1.0 / 5 spd
165,000 miles


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 Post subject: Re: Rebuilding the 95
PostPosted: Thu Mar 31, 2011 11:26 pm 
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Joined: Sun Mar 14, 2004 12:49 pm
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Location: Monroe, WA
More pics! I started on the head.


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I decided to do a little porting (nothing serious) once I saw all the sharp corners and rough edges in the pockets.


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Malcolm

'95 Metro 1.0 / 5 spd
165,000 miles


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 Post subject: Re: Rebuilding the 95
PostPosted: Wed Apr 20, 2011 2:01 pm 
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Joined: Thu Jun 22, 2006 4:38 pm
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Location: Gloucester, Virginia
95-3banger wrote:
I got kits on eBay. The trans kit was $172 I think. Don't do like we did and use 2nd gear to stop the gears to find first. Second gear was really worn out and I had to replace it. Not everyone has a spare trans to rob pieces from.

Glad you posted that. Using second to find first was how I was taught to drive a manual many, many moons ago.


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 Post subject: Re: Rebuilding the 95
PostPosted: Sun May 29, 2011 10:20 am 
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Joined: Tue Oct 24, 2006 3:09 pm
Posts: 4998
Location: Palm Springs: Too hot from June to Oct.!
Nice thread!

Here's a couple of recommendations:
First, To clean aluminum parts, next time, instead of warm 'Tide', try a warm solution of plain old 'Simple Green'.
Second, instead of Bosch Platinum spark plugs, try the recommended NGK spark plugs for your particular application:
http://www.ngksparkplugs.com/part_finde ... efault.asp

I've had favorite plugs in the past, but have learned by reading the posts on Teamswift what works and what doesn't.
Apparently, the NGK plugs seem to be quite appropriate; not sure why.
Let me tell you, it is sometimes humbling to have to admit that the 'other guys' were actually right! :shock: :shock: :shock:

Last, how's that engine and transmission holding up and what kind of mileage are you getting?

Again, great thread and hope to hear your positive feedback soon............ :thumb2:

_________________
DIY Broken Bolt Removal: viewtopic.php?f=22&t=41042
DIY Clutch Adjustment: viewtopic.php?f=9&t=48281
DIY Wheel Bearings: viewtopic.php?f=2&t=29003
DIY Shocks: viewtopic.php?f=10&t=45483
DIY Wheel Align: viewtopic.php?f=2&t=42479
Once you get the cars dialed-in (compression, leaks, bearings, alignment, brakes) swap in new rubber and glass, you've got something which should last for years!


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 Post subject: Re: Rebuilding the 95
PostPosted: Sun May 29, 2011 2:05 pm 
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Joined: Fri Jan 15, 2010 2:26 pm
Posts: 342
Location: TX-USA
+1 on the NGK plugs, either the copper or copper V-power run really well in these engines. The platinums will give a bit more life, but not sure if worth the extra cost.

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'99 Metro Sedan Auto 4cyl, '91 Metro Vert 3/5, '91 Metro 5dr 3cyl auto


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 Post subject: Re: Rebuilding the 95
PostPosted: Mon Jun 06, 2011 10:20 am 
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Joined: Thu Jun 22, 2006 4:38 pm
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Location: Gloucester, Virginia
Phil N Ed wrote:
Here's a couple of recommendations:
First, To clean aluminum parts, next time, instead of warm 'Tide', try a warm solution of plain old 'Simple Green'.
:thumb2:


I work in Military Aviation and we have found that Simple Green actually increases the rate of corrosion on Aluminum. Used to use it all the time to cut through the grease and dirt on helicopters, now we are strictly forbidden to use it.


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 Post subject: Re: Rebuilding the 95
PostPosted: Mon Jun 06, 2011 12:06 pm 
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Joined: Tue Oct 24, 2006 3:09 pm
Posts: 4998
Location: Palm Springs: Too hot from June to Oct.!
GTDave wrote:
Phil N Ed wrote:
Here's a couple of recommendations:
First, To clean aluminum parts, next time, instead of warm 'Tide', try a warm solution of plain old 'Simple Green'.
:thumb2:


I work in Military Aviation and we have found that Simple Green actually increases the rate of corrosion on Aluminum. Used to use it all the time to cut through the grease and dirt on helicopters, now we are strictly forbidden to use it.

Thanks for the comment.
Here's the link you are talking about:
http://www.chinook-helicopter.com/maint ... aners.html
If you follow the links, it's a LONG read, and I've done it in the past.
It is a blast back to the past...1992, I think.
He is not working on a Boeing CH-47.

Partly as a result of that issue, they developed this:
http://industrial.simplegreen.com/ind_p ... xtreme.php
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(at least according to my aerospace engineer nephew who designs military aircraft)
BTW, the part that brought down that particular helicopter was re-engineered.

Toward the beginning of the Century, I drifted away from diesel and gasoline, and started using Tide as a cleaning agent. These days, I find the Simple Green solution superior.
That's my experience and what I recommend for the younger generation on ground and water craft.

Say, since we're resurrecting this old thread, what ever happened to that transmission? Shifting smooth as glass?

_________________
DIY Broken Bolt Removal: viewtopic.php?f=22&t=41042
DIY Clutch Adjustment: viewtopic.php?f=9&t=48281
DIY Wheel Bearings: viewtopic.php?f=2&t=29003
DIY Shocks: viewtopic.php?f=10&t=45483
DIY Wheel Align: viewtopic.php?f=2&t=42479
Once you get the cars dialed-in (compression, leaks, bearings, alignment, brakes) swap in new rubber and glass, you've got something which should last for years!


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 Post subject: Re: Rebuilding the 95
PostPosted: Mon Jun 06, 2011 2:45 pm 
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Joined: Thu Jun 22, 2006 4:38 pm
Posts: 145
Location: Gloucester, Virginia
I don't know about that message for sky taxis, but we were using it on scout helicopters as late as 2002.


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 Post subject: Re: Rebuilding the 95
PostPosted: Mon Jun 06, 2011 3:27 pm 
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Joined: Tue Oct 24, 2006 3:09 pm
Posts: 4998
Location: Palm Springs: Too hot from June to Oct.!
First, I'm no 'expert' when it comes to working on engines.

I did grow up in an area where many people make a living working on cars (Los Angeles).
In the larger shops which rebuild hundreds of engines per month, they use a commercial cleaner due to pressure from the 'environmentalists'.
Not wishing to piss off the 'green machine' I asked the guys in the shop what the 'environmentalists' forced them to use.
They said it was necessary to stop using carbon tet, gasoline, and other cleaners due to the problem of waste disposal.
"So what did you have to switch to?"
They answered, "Industrial Strength Simple Green, but you can use the plain stuff as well."
I couldn't believe my ears, as I'd seen it in the grocery store, but never used it.
I asked if there was any downside. They told me it worked better warm, but other than that, it was OK.

I am not here to reinvent Science or searching for that one in a million medical cure for cancer, so in this case, it was easy to take their advice, as the Simple Green is available at Home Depot, etc. Although it took me several years, and I tried a few detergents (including Tide) along the way, eventually I threw in the towel and gave it a shot.

Similar results with Mobil One. I HATED to hear from the members who kept saying Mobil One blah blah blah.
They seemed so 'stuck up' and I didn't see how I could afford it.
Eventually, I gave it a try and now I use it exclusively. Pretty frickin embarrassing, but true.

I keep trying to shut this computer down
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but the anticipation is KILLING me...
SO, :shock:
What the hay happened with this guy's transmission?

_________________
DIY Broken Bolt Removal: viewtopic.php?f=22&t=41042
DIY Clutch Adjustment: viewtopic.php?f=9&t=48281
DIY Wheel Bearings: viewtopic.php?f=2&t=29003
DIY Shocks: viewtopic.php?f=10&t=45483
DIY Wheel Align: viewtopic.php?f=2&t=42479
Once you get the cars dialed-in (compression, leaks, bearings, alignment, brakes) swap in new rubber and glass, you've got something which should last for years!


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 Post subject: Re: Rebuilding the 95
PostPosted: Tue Jun 07, 2011 11:20 pm 
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Joined: Sun Mar 14, 2004 12:49 pm
Posts: 189
Location: Monroe, WA
Now why on earth would I pay through the nose for Simple Green when I can steal Tide from above the washer anytime I need it??? :P

It's been 'done' for a few weeks now, but the story has a sad ending. I drove it for 2 days without any real problems but on the 3rd day the 1 and 2 syncros decided they were done working. I've been driving around shifting slow into 1st and 2nd. I let the wife drive it to work for a few days. When she filled it up we got the next shocker, 28 mpg!!! I said 'come on!' Must be something haywire. I drove it and at the next fill up it only got 26!!!!!! This has spiraled down to the point I replaced the fuel pump (cuz of some funny in tank sounds) and tonight pulled the exhaust to check for a plugged converter due to the rich running. No change, except it's down on power now and sputtering after 1/2 throttle when revved up. I'm out of ideas at this point and back to driving my gas hog till I figure something out. :(

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Malcolm

'95 Metro 1.0 / 5 spd
165,000 miles


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 Post subject: Re: Rebuilding the 95
PostPosted: Wed Jun 08, 2011 1:03 am 
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Joined: Tue Oct 24, 2006 3:09 pm
Posts: 4998
Location: Palm Springs: Too hot from June to Oct.!
You have some great posts here, and I'm sure you'll sort this out.
Think positive and take it one step at a time.

_________________
DIY Broken Bolt Removal: viewtopic.php?f=22&t=41042
DIY Clutch Adjustment: viewtopic.php?f=9&t=48281
DIY Wheel Bearings: viewtopic.php?f=2&t=29003
DIY Shocks: viewtopic.php?f=10&t=45483
DIY Wheel Align: viewtopic.php?f=2&t=42479
Once you get the cars dialed-in (compression, leaks, bearings, alignment, brakes) swap in new rubber and glass, you've got something which should last for years!


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 Post subject: Re: Rebuilding the 95
PostPosted: Thu Jun 09, 2011 12:29 am 
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Joined: Thu Jul 20, 2006 7:17 pm
Posts: 1403
Location: Alberta, Canada
Did you replace oxygen sensor? That and cat convertors take a beating from past engine misfiring and oil burning. I do a lot of engines and the odd time one or both of these act up a bit after the car gets back on the road again.
I've done quite a few trannies, just first and second gear synchro and have had great results. I'm surprised to hear they arent working well on yours. I use dealer parts, as I am just doing a few things in them, wonder if the aftermarket synchros are just a bit off of the oe ones?

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1995 Swift w/16V 4.39s, 3tech cam, Esteem t-body, Header, needs more.
1995 Gt Mustang "Boss Shinoda" package.
1999 F150 4x4 Supercharged
1967 Mustang 428 auto, never ending expensive project
1993 Civic si h22a, fell in my lap, couldn't resist!


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 Post subject: Re: Rebuilding the 95
PostPosted: Sat Feb 25, 2012 3:33 pm 
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Location: Monroe, WA
Hey, I'm still alive! Car still runs (sort of). I have been doing some testing and part swaping trying to find the rich running issue. I probed the O2 with my meter and it 'sees' the rich running (straight to .9volts as soon as you rev) so I doubt that's it. More than one person had said the injector could be letting too much fuel out so I tried another one, broke both screws trying to get that plastic cover off! They didn't have to drown them in locktite!!! So I swapped in the other injector and zip-tied the cap on to try it. With the meter on the O2 it does the same thing. I've ordered a MAP sensor from Napa ($63) it should be here today. It must be going nuts when I rev it up and signaling way more fuel than it needs, cuz at idle I'm getting a normal O2 reading.

Luckily I have the rest of the TB that I took the other injector out of at work. I managed to NOT break those screws, so I'll swap it onto the car so I don't blow the injector out and die in a horrible fire. :)

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Malcolm

'95 Metro 1.0 / 5 spd
165,000 miles


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 Post subject: Re: Rebuilding the 95
PostPosted: Tue Feb 28, 2012 3:23 pm 
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Joined: Thu Jun 22, 2006 4:38 pm
Posts: 145
Location: Gloucester, Virginia
Not sure if some of the questions are in regards to my transmission, but to answer if they are.
I have not yet had time to rebuild my transmission or engine due to military obligations, and that's all I'm sayin'. :twisted:

I'm hoping to get down to the local pick-n-pull in the next couple of months and just grab an engine and trans and do a bench top rebuild as I find time.


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