Re: 1992 2.1 Sd Auto Estate
Posted: Fri Oct 23, 2026 7:09 am
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 done' 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 he 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.
I found a coupling so replaced it, but in case others done' 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 he 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.