On pulling the subframe back the hydraulics return rubber coupling split so started dripping LHM. I placed a catch tray under it to catch it until I located a replacement coupling.
I found a coupling so replaced it, but in case others don't have one have taken measurements.
The pipes are just push fit, but surprisingly difficult to push in. I used a pair of curved grip pliers behind the flare and then pushed the pipe using those.
The coupling is a barrel with a manifold on the side.
the barrel length is 54mm, by 15.5mm diameter, the manifold is 37mm by 11mm and 28mm overall from the back of the barrel section.
The outlet barrel section reduces diameter to 12mm.
The pipe ports are 5mm and one of 4mm.
I don't think any of the measurements are critical as long as it links the nylon pipes together and fits in the space.
I then tackled the rust in the rear member cruciform area.
I drilled out the spot welds and removed the plates which revealed the condition of the longitudinal members. These are a known weak spot on XM, as they have minimal protection and no seam sealer, so water from the rear wheels migrates into the joints.
On both sides the right side the forward member was significantly corroded and the left rear one was too, but the rear right side one only had surface corrosion and took some effort to bend it back into the correct position.
The images show the condition as first revealed then after wire wheeling.
I cut out the rot and cleaned up the remaining metal.
Removing the reinforcing plates had buckled them so I cleaned and straightened them to inspect. There is some light pitting, but I don't think it warrants replacement.
1992 2.1 Sd Auto Estate
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Dieselman
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Re: 1992 2.1 Sd Auto Estate
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91 3.0 sei M. 4852 EXY Black
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
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90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
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Dieselman
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Re: 1992 2.1 Sd Auto Estate
Before welding I am ensuring all surface corrosion is dealt with: firstly rust removal using an engraver and mild acid to chip and vibrate the rust out, then if necessary I will use a rust converter.
I have completely removed the rust on the right side sections and am starting on the left side, which has more surface rust at the cruciform and lower chassis rail sections. I suspect as well as more road dirt being thrown up, when the car was sat resting for 20 year, there was vegetation growing at that side.
Before painting I will smooth the engraver roughness using wet'n'dry paper.
Inside the box sections is almost perfect.
Still to do.
I have completely removed the rust on the right side sections and am starting on the left side, which has more surface rust at the cruciform and lower chassis rail sections. I suspect as well as more road dirt being thrown up, when the car was sat resting for 20 year, there was vegetation growing at that side.
Before painting I will smooth the engraver roughness using wet'n'dry paper.
Inside the box sections is almost perfect.
Still to do.
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91 3.0 sei M. 4852 EXY Black
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
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Dieselman
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- Joined: Thu Jun 18, 2009 6:44 pm
Re: 1992 2.1 Sd Auto Estate
More cleaning up of the surface rust and painting inside the box section with primer.
Before welding I will need to clean the primer from the edge of the metal back for about 10mm, both to ensure a good electrical connection and to stop it setting fire inside the box, which could be awkward to deal with.
After cleaning up the rust I found the reinforcing plates to be significantly thinned on the lead tongue and one is holed.
After aggressively removing rust I found a single pin hole through the left wheel-house panel. I'll remove the wheel-arch liner cleanup and weld this. It has been caused by a single water spot corroding the metal.
Before welding I will need to clean the primer from the edge of the metal back for about 10mm, both to ensure a good electrical connection and to stop it setting fire inside the box, which could be awkward to deal with.
After cleaning up the rust I found the reinforcing plates to be significantly thinned on the lead tongue and one is holed.
After aggressively removing rust I found a single pin hole through the left wheel-house panel. I'll remove the wheel-arch liner cleanup and weld this. It has been caused by a single water spot corroding the metal.
You do not have the required permissions to view the files attached to this post.
91 3.0 sei M. 4852 EXY Black
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
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Dieselman
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Re: 1992 2.1 Sd Auto Estate
New metal cut, shaped and welded in. Where I left the existing metal I welded in the drill holes using 5mm bolts as the filler.
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91 3.0 sei M. 4852 EXY Black
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
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Dieselman
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Re: 1992 2.1 Sd Auto Estate
As I only have a finite stock of thicker metal plate I set about replacing the corroded forward tongue of the cruciform reinforcing plate.
After cutting some pieces of metal, to ensure correct alignment I tacked them onto the original plate before cutting through both pieces, then tacked the new metal onto the existing, before cutting through the tack welds and fully welding the new plates on.
I cleaned out the single pin hole in the inner wheel-house and plug welded that from both sides, then after fettling all new welds and test fitting the cruciform plates, to ensure any remaining rust spots are inert, painted all the previously cleaned/acid treated areas with rust converter.
I'll see any rust conversion once the converter is dry.
After cutting some pieces of metal, to ensure correct alignment I tacked them onto the original plate before cutting through both pieces, then tacked the new metal onto the existing, before cutting through the tack welds and fully welding the new plates on.
I cleaned out the single pin hole in the inner wheel-house and plug welded that from both sides, then after fettling all new welds and test fitting the cruciform plates, to ensure any remaining rust spots are inert, painted all the previously cleaned/acid treated areas with rust converter.
I'll see any rust conversion once the converter is dry.
You do not have the required permissions to view the files attached to this post.
91 3.0 sei M. 4852 EXY Black
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White
92 2.1 sed M. 5740 ECZ Sable Phenicien
92 3.0 V6-24. 5713 EXY Black
92 2.1 sd M. 5685 ENT Blue Sideral
Prev
90 2.1sd M. 5049 EJV Mandarin
92 2.1sd A. 5698 EJV Mandarin
94 2.1sd A. 6218 ERT Triton
91 2.0si M. 5187 EWT White