A Hole

[parrot820]

I'm busily taking the engine apart, now that I've got it out of the frame.
Nothing terribly alarming so far, although the state of the stator was a bit of a shock:


That should be really easy to either clean or replace.

I haven't really done anything more than take things apart at this point, but I'm getting close to doing real work, whether it's just cleaning or reading up on what the whole "2nd gear" fix is that I keep reading about.

Before I dig deeper, I do need to know one thing.
Should there be a small hole at the back of the lower engine case?



The doesn't seem right, but it's the only sign of damage on the whole engine, the rest is just cruddy and needs lots of cleaning.

If it's not supposed to be there, then I should probably source a replacement case and deal with that before worrying about any other work.
It will also mean I'll be digging a lot deeper into the engine than I had originally planned if I now need to transfer all parts from one to the other case.

[DiverRay]

I would NOT replace the case, but look into putting a "patch" on the hole. JB Weld should hold up as long as you would need it, just clean the case really well with de-greaser BEFORE trying to patch it. I would put the patch on the outside, as it's in a place that cannot be seen. JMHO

[trbig]

I saw the title of this thread and thought someone was calling my name...

I agree with Ray. I would make sure to pull the oil pan and take a look there to see if something came loose and made the hole there from the inside,(And to also see if the bottom end of the motor is as rusty as the rotor) but something to simply plug the hole is all you need... and that's only if it goes all the way through. It may have just been a defect in the molding/casting process... or a kid with too much time on his hands and a high powered BB gun.

The rotor, I'd simply spray it off with some brake cleaner. Same thing with the stator. DON"T use sandpaper on the stator. The wires are covered in resin, and it's easy to ruin the stator if you use sandpaper around the part that the rotor spins next to. A little rust shouldn't hurt anything in there.


Tod

[parrot820]

Just wanted to follow up regarding the hole.

I just yesterday turned the engine over reversed from how I had it before, so I'm getting a different angle on things. I took another look at the hole and noticed I could see threads from this new angle.



I looked from the other side, and sure enough, there's the bolt hole that somehow managed to push right through:



Whew! I can live with that. It wasn't caused by some internal part, which was my main concern. Well, that and oil spewing out all over the place.

So, I'm gonna jb weld it up and that should take care of it.

[Ivan]

that hole is my case as well. it is from the hole drilled in for the middle drive bolt. its no big deal.

[parrot820]

The rotor, I'd simply spray it off with some brake cleaner. Same thing with the stator. DON"T use sandpaper on the stator. The wires are covered in resin, and it's easy to ruin the stator if you use sandpaper around the part that the rotor spins next to. A little rust shouldn't hurt anything in there.
Tod

OK, I feel a bit silly asking this, but how do I get the stator out of the case?
I've removed the outside three bolts and also the inside 4 and it won't budge. It's quite rusty, so is it just really wedged in there, or did I miss something?
I did pb blast it a bit, but the whole thing's rather awkward and fragile so I don't want to force it too much.

[Geezer]

Heat the case up with a heat gun and it should fall out. You may need to slam the case down on the floor to pop the stator out but that should be a last resort.

Geezer

[Jerry]

From a previous thread:
***********
So everyone can see what is required, it is as simple as a bolt, the one you need is a 16mm standard fine thread [has a pitch of 1.5, it will also have 8.8 stamped on the head].

The only thing that will help lots, will be to grind/file the concave end off the thread [you will have to clean the thread end], to make it sit flat on the crank end so it will pull straight, load up the bolt & tap with a hammer with a piece of timber under it [you don't want metal on metal] and Bobs' your Uncle.
********

I used this method to pull the rotor on my XJ. Screw in the bolt, tighten it up, tap the end of the bolt and the rotor pops off.

[81xsproject]

The bolt method mentioned by Jerry is king. I beat on for days before getting the bolt. It wasn't easy to find, but once I had it, the stator rotor was off in seconds.

[parrot820]

Heat the case up with a heat gun and it should fall out. You may need to slam the case down on the floor to pop the stator out but that should be a last resort.

Geezer

Thanks for the info on how to remove the rotor, since I may need to do that as well.

However, Geezer's hint is what I was needing in this case. I don't have a heat gun yet, so opted for the "short-sharp-shock" method of (gently) slamming it onto some cardboard. That was enough to get it moving and I was able to unwedge it the rest of the way with my hands.

I just didn't want to use too much force and find out later I needed to turn it a 1/4 turn and it would just fall out.

Thanks much!