Dino3310

well no key sheared, key and shaft look good, harmonic balancer stuffed

well mate after tonight i think i can say i totally misdiagnosed this one. i put the pump back together and back in the truck started her up and it made the noise again soooo i took the belt of again and started her up only this time i hopped out and revved her from the throttle linkage on the injector pump...... thats when i noticed the alternator belt and pulleys weren't turning properly, to the point i could stop it altogether by stopping the fan by hand {not recommended} so i then took the alternator belt of and found i could turn the crank pulley by hand and very easily. so im thinking that the pulley key has sheared of which might have been started by the ac unit seizing a couple years back and it gradually wore out what was left...... i think that makes sense, ill find out tomorrow when i get some time to get into it. on a positive note; i got to find out how the internals of the PS pump work and look like :-)

I disconnect the belt to th ps and the noise disappeared, hooked it back up and it was back.

Found a diagram, no bearing from what I could see. Got me buggered whats wrong. Will hunt around for a second hand one

power steering.................................. making a prick of a noise, graunch/crunching sound at around 1500-2000 rpm then disappears, it has been building for a while. there No whining or humming like the classic air bubble its a metallic grinding sound like something spinning and catching. anyway i pulled it apart as i suspected one of the vanes had come out and was grinding around, i was wrong it looks tidy and everything in its place. where im stuck at is, is there a bearing or a bush at the front and how the hell does the front pulley nut come of, is it one of those reverse threads and ive been trying to force it tighter or do i need to give it more muscle. the front bush/bearing seems to be my last port of call to check as everything else seems to be fine. anyone know where a schematic diagram of the pump is online cheers Dino

i didnt know at first as a mate gave me a 20litre container of the stuff he uses at his job, been in my garage for the last 6months. when i realized it could be the oil i got a hold of him he said it was 'Castrol super Torque' so far so good, dipstick shows clean oil, truck running sweet...... well until the alternator decided to die yesterday..... it never ends with this thing, must be at that age where everything needs replacing around the motor lol

went into town heading to my mates workshop..... tranny ran fine, after half an hour or so driving it played up a little. i figured it must have been the oil from the change i did as i didnt have any problems before that or maybe there was a bit or crud in the system blocking a gallery, so i went straight to the auto store and brought some dexron3 oil, i got enough to fill it twice as i wanted to flush all of the old @!*% out. got home and flushed it till the ugly oil was gone and only the good stuff coming out. did a short drive to check level and the a 3hour drive and shes running sweet, check dipstick oil level good and oil color perfect so im very happy with the results and learnt a lesson on using correct spec oils.

update. going into my mates garage next week, dropping the sump etc, will let you know what we find

Mmmmm could be a prime opportunity for a manual conversion, any difficulties with that as there's a few floating around at the moment and a lot cheaper than the autos

Thanks guys I appreciate the feedback

Makes sense, I'll have a look at the manual after work, what about the stuffed oil would the solenoid issue cause it

are the later(97 up) model tdi engine transmissions compatible with the earlier ones

cheers mate yeah i havent done any towing, just easy driving mainly flat roads and just cruising, no heavy loading. i just did the 'self diagnostic" procedure as per in the manual, its has a long light on the 7th flicker which the manual says its the 'Torque converter clutch valve is short circuited or disconnected' im pretty sure its a bit more than just that LOL i'll start looking around for a low mile 2nd hand one, ive looked at fully reconed ones but there cost is ridiculous

Hi Guys Ive got the 95 td27 with auto transmission... i think my tranni just died? about 2 months ago i did a fluid flush after it stuttered a bit in o/d, the fluid that came out was looking a off being a bit brown instead of reddish, after the flush its been running great ive done around 2000klms and its been running as it should but today i went for a 20 minute drive into town all was well but when i left town the o/d wouldnt work and 1st wouldnt work so im guessing that was limp mode, after arriving home i checked fluid levels(all good) let it cool down then went up the road a little and now the torque converta aint working too as i have to flick her into neutral to stop her stalling at near stand still, when i managed to get her back up my drive i drained a couple liters of oil to see what she looked like figure it should still be a reasonable color since been new oil 2 months ago but no it was a dark chocolate brown in color!!!! does this sound like a stuffed transmission? cheers Deano

mine had a similar sounding problem after i had my starter rebuilt, after a few headaches replacing various parts we found that the thing was spinning in reverse, the bush sets were wired backwards... ended up buying a new starter.

Turns out the replacement replacement bushes were wired the same so backwards to the original, he couldn't source an like for like set so he did me a good deal on a new starter motor, shes a slow old pig but she starts perfect now :-) thanks for your input guys

Not long returned from the auto shop. We stripped it and compared to the old parts, apples to apples, he found the replacement bushes were hard wired opposite to the original, which he says was making it run backwards...... So new set ordered and hopefully be here in a couple days

Thought so, i'll get it back in to the shop and get another pillion gear. im pretty confident the solenoids all good as this is the third different one ive had on it since ive had this problem.

Is the pinion gear ment to turn both ways as I can turn mine backwards by hand!!!

Cheers mate, everything looks good, tried direct hook up of leads/power etc, only thing I can think of now is the pinion clutch might be poked, when on the bench testing it throws the gear out to about 6-7mm short but when I test it without the spin just the igniter it throws out %100 😵

Hi Guys, just had the starter recond - new bushes and solenoid as the old solenoid was playing up and while it was on the bench we checked the bushes and they were near stuffed so we replaced those too, testing on the bench everything works perfectly but when i bolt it up to the engine all it does is spin or the ching ching noise like its not engaging flywheel, work was done by an auto electrician we've pulled it out and stripped it 3 times to make sure all the bits are in there correct places etc, its got us stuffed why it wont engage. anyone else had this problem and resolved it, i cant afford a new starter at the moment so if theres a simple fix we've over looked please share. cheers Deano

i blocked mine at the intake end. access thru the wheel well. heres a vid i found useful

Gidday Fellas, im Deano from NZ, ive visited site a few times and thought id might as well join, hopefully there will be topics/threads i can contribute to as well. i Have a 95 Mistral TD27, R20. some places known as the terano2 or ford Maverick. Brought it a couple years ago, mainly used as a daily commute and weekend hunt or fish wagon. not the fastest or gruntiest but it goes and goes and does whats required of her. the only mods so far is Blocking of the ERG valve, sealing up sunroof and upgrading the glowplug timer and relay. Has a couple of issues but i'll have a good search through the site before posting any questions up. Looking forward to chatting to you and contributing to this great site. cheers Deano