Now that’s a lot of parts!

[Googlebot]

Will be commencing operation sort the van out next week.

I have a full service to do, including all filters.

In addition, the radiator I fitted 3 years ago appears to be leaking again which is frustrating so that’s being changed.

Both front shock absorbers were advisories on the last MOT so new ones are here.

It’s done 76,000 miles, while it’s up in the air with the driveshafts separated from the hubs, the gearbox is coming off and a new clutch is going in.

It also needs the brake/clutch fluid replacing so that’s being done too.

There is a small amount of oil coming from one side of the intercooler pipes, so that might be swapped out too while it’s off for the radiator replacement.

The USB connector has fallen out the head unit for Apple car play.

The solenoid valve on the toilet is letting by slightly so that’s being changed too.

Close to 1k in parts.

I dread to think how much it would be at a garage. Wish me luck!

 

[Figaro]

There is a small amount of oil coming from one side of the intercooler pipes, so that might be swapped out too while it’s off for the radiator replacement.

I have similar, no other symptoms, what are you swopping out ?
I had wondered if I should remove the pipe and reseal the connection to the intercooler

 

[LithiumConvert]

You obviously seem to very happy with Hymer Exsis to do all that work.

We used to have a 576 which we were very happy with, and would sill have it now if I could still drive a manual gearbox.
In my opinion, the 580 is not quite as good - but we found one with the 9 speed auto.

The fact that the 580 has a factory fitted B2B, very much simplified moving the LiFePO4 batteries from one to the other.
I used your guide as the basis for installing the lithium in the 576.

Good luck with such a lot of parts

 

[Googlebot]

I have similar, no other symptoms, what are you swopping out ?
I had wondered if I should remove the pipe and reseal the connection to the intercooler

I meant the pipe to the intercooler, from what I have read a little oil is normal as it’s the lowest point for it to gather. I think the pipe is just perished or the clip isn’t tight enough from when I last changed the radiator. I will update when it’s in bits.

You obviously seem to very happy with Hymer Exsis to do all that work.

We used to have a 576 which we were very happy with, and would sill have it now if I could still drive a manual gearbox.
In my opinion, the 580 is not quite as good - but we found one with the 9 speed auto.

The fact that the 580 has a factory fitted B2B, very much simplified moving the LiFePO4 batteries from one to the other.
I used your guide as the basis for installing the lithium in the 576.

Good luck with such a lot of parts

Thanks, I am very happy with the van and I like to look after it. It is now 12 years old and is to be expected on a vehicle that old I suppose.

I did consider changing it, but have read so many horror stories about newer vans I daren’t risk it. We do 9000 miles a year and use it all the time, it’s well worth the time and money for me looking after it.

Things not working perfectly also drive me nuts!

If it all goes wrong, there are lots of mobile mechanics locally.

 

[LithiumConvert]

I did consider changing it, but have read so many horror stories about newer vans

This is not the place for tales of horror stories, but I can say that two years downstream, we have [almost] everything fixed.
A steep learning learning curve, but I now know how a lot more of it works.

Once again. many thanks for your lithium guide (with photos).

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[Googlebot]

This is not the place for tales of horror stories, but I can say that two years downstream, we have [almost] everything fixed.
A steep learning learning curve, but I now know how a lot more of it works.

Once again. many thanks for your lithium guide (with photos).

Glad it helped and also glad your van is now working well.

I will update with pictures as I sort it out, the forum is full of people who know what they are doing. When I rewired to use the inverter, I had loads of help thankfully as I nearly hashed it right up.

 

[Growly bear]

In my opinion, it's only when yi6u invest blood, sweat and tears that you truly love it. I'm in the middle of fitting new solar to mine. Ive then got a full service and Comfortmatic fluids too Inc kiss etc.

Are you swapping out the front springs too? I remember a thread a while ago re Lenny's springs.

 

[Googlebot]

In my opinion, it's only when yi6u invest blood, sweat and tears that you truly love it. I'm in the middle of fitting new solar to mine. Ive then got a full service and Comfortmatic fluids too Inc kiss etc.

Are you swapping out the front springs too? I remember a thread a while ago re Lenny's springs.

Keeping the springs, they are Goldschmidt so good quality, if in doubt when I have a good look they are going and will be replaced. Probably not Goldschmidt though.

 

[Growly bear]

Keeping the springs, they are Goldschmidt so good quality, if in doubt when I have a good look they are going and will be replaced. Probably not Goldschmidt though.

They are crazy money!

Ive no idea what's on mine. I don't know whether it's because it's a 3 litre with robot but the front is lower than I'd like and a little crashy at times. In thr future when I've saved up I'd like to swap them out...

 

[Googlebot]

They are crazy money!

Ive no idea what's on mine. I don't know whether it's because it's a 3 litre with robot but the front is lower than I'd like and a little crashy at times. In thr future when I've saved up I'd like to swap them out...

The front is lower on mine too.

I haven’t got the cash for the replacement Goldschmidt springs though. Might go genuine Fiat if I have to.

The shockers are leaking oil so I am hoping that improves the ride.

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[Landy Andy]

Klein do springs that raise 50mm. Happy with them on mine.

 

[Googlebot]

Started today as the weather looks naff over the bank holiday.

Started with the hub nuts, already broke my breaker bar on them last time I had to get them off, I have now also bent the new one. They are tight!

Decided to change the brake and clutch fluid next, no point putting old stuff in a new slave cylinder. If you haven’t got an easy bleed, they make changing the brake fluid an absolute doddle. Had it over 20 years and still going strong.

I know it’s filthy, it will be cleaned once I have finished.

The clutch fluid that I bled out was black! I have changed the brake fluid before but the clutch bleed is difficult to get at so I didn’t do it. I should have! It’s below the air filter housing here.

 

[Googlebot]

Next it was off with the suspension components and hubs. Not so bad if you have done it before, the battery impact gun is amazing!

Driveshaft is now out too after draining the gearbox of oil.

The other side took some persuading out the bearing housing with a big hammer.

 

[Googlebot]

Being as paranoid as I am I have 4 axle stands and 2 spare jacks holding it up. Being squashed underneath it isn’t part of my plan!

The gear linkages are right at the back, just pop off easily.

With the engine supported, another jack below the gearbox and it’s off and out with the bell housing and gearbox.

 

[Googlebot]

Annoyingly, the new clutch I had waiting is the wrong one. GSF have got the right one, (now I have the part number) on order and will be here tomorrow. It’s £200 more though typically. The old one wasn’t all that worn, the release bearing was noisy though so it was worth taking the box off and the expense of changing it.

I should be good for another 12 years now clutch wise and should see the life of the van out.

Spent some time organising and tidying as well or I forget which bolt goes where.

The pile of parts taken off is growing as well.

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[Googlebot]

Shockers and radiator are going to be going on tomorrow and I need to check the intercooler pipe.

Hopefully done by Sunday all being well.

Not looking forward to dismantling the interior to get at the top mount bolts, I am a clumsy oaf and normally break stuff like trim. :-(

 

[Bobby-gg]

Is yours the 2.3L, or the 3L? I cried taking the gearbox out myself on my 3L, and even more so putting it back in, twice

 

[Googlebot]

Is yours the 2.3L, or the 3L? I cried taking the gearbox out myself on my 3L, and even more so putting it back in, twice

It’s the 2.3, I am hoping for no tears.

I reckon it’s 60kg at least that box. I am eating my weetabix….

What happened with yours?

 

[Bobby-gg]

It’s the 2.3, I am hoping for no tears.

I reckon it’s 60kg at least that box. I am eating my weetabix….

What happened with yours?

Changed the clutch & flywheel (manual) and then dropped the box out again as the brand new slave cylinder just wouldn't bleed for some strange reason, swapped it for another and that bled no bother.

I think the 3L is a bit longer engine, the gearbox is a very tight fit

 

[Googlebot]

Changed the clutch & flywheel (manual) and then dropped the box out again as the brand new slave cylinder just wouldn't bleed for some strange reason, swapped it for another and that bled no bother.

I think the 3L is a bit longer engine, the gearbox is a very tight fit

Good advice, will bleed it before putting all the bolts and ancillaries back on.

I did have to drop the engine a bit to miss the body. You’re right, it was a bit tight with a heavy box.

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[Bobby-gg]

Good advice, will bleed it before putting all the bolts and ancillaries back on.

I did have to drop the engine a bit to miss the body. You’re right, it was a bit tight with a heavy box.

If I ever have to take the box out again I'll drop the full engine & box out together - I've got a forklift which will certainly help!

 

[Googlebot]

If I ever have to take the box out again I'll drop the full engine out - I've got a forklift which will certainly help!

Wow, I am hoping it won’t come to that.

 

[Landy Andy]

Not looking forward to dismantling the interior to get at the top mount bolts, I am a clumsy oaf and normally break stuff like trim. :-(

You may have security nuts on the frame around the fuse board. I did on mine.

 

[Googlebot]

You may have security nuts on the frame around the fuse board. I did on mine.

I was hoping to get enough space to avoid taking it out. Did you manage to drill them out?

 

[Landy Andy]

I was hoping to get enough space to avoid taking it out. Did you manage to drill them out?

I used side cutters (wire cutters). Decent size quality ones, onto the head at 90 degrees, and got enough purchase that they came out. I was surprised how untight they were.

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[Googlebot]

I used side cutters (wire cutters). Decent size quality ones, onto the head at 90 degrees, and got enough purchase that they came out. I was surprised how untight they were.

Excellent!

Fingers crossed then.

 

[Googlebot]

Well, the good news is that the security bolts were already gone.

This was the passenger side top mount.

 

[Googlebot]

Springs seemed in good condition overall. The shockers however were absolutely knackered! Rough travel that could easily be pushed by hand and they don’t expand again. Renewed the top bearings and top mounts too while they were off.

 

[Googlebot]

The right clutch arrived, cost £420 alone just for the clutch kit.

Here it is fitted and the gearbox ready to go back on.

The gearbox was an absolute arse to get back into position.

No centre of balance to put a jack on and way too heavy to throw up.

There is a guy on YouTube, Kevin Albert-Williams, he just lifts the box, on his knees and up. I ended up sort of doing that but Jesus it was hard work!

Anyway, it’s back on and bled. Bleeding took some time and had to use the clutch pedal to get the air out the new slave cylinder.

 

[Googlebot]

Here is the left hand side all back together with new hub nut.

Just the right side to put back together now and the radiator to change.

New gearbox oil is in as is the engine oil and filter changed.

Phew! Knackered now.

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