2002ti wannabe project begins

[M3M3]

they dove right into the project!

[jgerock]

23 hours ago, M3M3M3 said:

they dove right into the project!

I only wonder if they will attempt to put the windows back in…

[jgerock]

Updated pictures received last night. Headliner installed. Upper anchors for belts in place. 

[jgerock]

Had to drive up to the shop today to help reinstall the two windows.  I brought my nylon rope and lockstrip tool.  Jaime (upholstery guy) was going to use the exact same cord.  He hasn’t done a VW or BMW window install in a very long time so he asked me to help.  We got the front done in about 45 minutes after a false start with the cord.  Rear window went in very fast. I was surprised how easy the rear one was. Granted, the last time I did this was about 2014/2015 in my garage with help from @MatthewCervi and @M3M3M3.  Having the headliner done professionally makes a huge difference. Hopefully, this is the final time for this car.  

[jgerock]

Car was retrieved last Sunday thanks to my wife who shuttled me up to Laurel.  During the week, I’ve reinstalled the rear package tray, the speakers, rear door panels and the back seat.  I also removed the gauge cluster (I’ve lost count how many times this makes).  While driving up to the upholstery shop, I noticed a buzzing noise from the cluster. It was the glass bezel rattling from after I put the fixed speedometer back in.  Hopefully this will solve the buzzing noise.

 

Right door panel removed and the glass adjusted just a tiny bit.  I have new door window winder handles which are much better than my old ones.  
 

The body shop installed the upper seat belt anchors higher than normal, so they simply removed the assist straps that fasten to the coat hooks.  I’m ok with that because nobody rides in my back seat and the same straps flap around in my tii with the windows rolled down.  
 

Next up: brake fluid flush and investigating a growling noise coming from the rear end.

[jgerock]

Flushed the fluid from the brakes and clutch yesterday👍.  Inspected the differential while stationary (on stands) and while running in gear.  Slight wobble from left output shaft.  Wheels not really acting like a limited slip should, so I pulled the diff today for a rebuild (Aardvarc). 😔

[saaron]

The headliner looks awesome!  

 

Re the diff - it’s always something.  

 

Cars look great as always!

 

Scott

[jgerock]

8 hours ago, saaron said:

The headliner looks awesome!  

 

Re the diff - it’s always something.  

 

Cars look great as always!

 

Scott

Thanks Scott! I see you will be going to Vintage next month.  If I don’t get the rebuilt diff back in time, I may just take the e30 again.

[jgerock]

New plastic door liner (2mil thick drop cloth from Home Depot) cut to fit and the new right side door panel has been installed after sitting in my basement for a long time.  Had to transfer the aluminum upper trim, clips and fuzzy window strip to the new panel, along with piercing holes for the (2) cranks, door opener and (4) screw holes.  I used the yellow panel clips which seem to work well. One thing I noticed about the new panel- it extends past the rear edge, contacting the door seal.  The front edge is fine.

 

New window winders installed. Got a set of these from Maximillian. They come in URO bags. They are similiar to the originals but the snap in black plastic trim piece is separate (comes with the handle).  I noticed the attachment screw included with the new handle is slightly too long which bottoms out before the handle gets tight, so I reused my old screws.  Picture below taken before the black insert was added to the handle.

 

Waiting for an update on the differential rebuild by Aardvarc.  If I don’t receive it before Vintage (happening mid May), I’ll drive either the tii or the e30. I have options😏.

[jgerock]

Rebuilt 2002 LSD received earlier this week. New bearings, seals and e21 spring washers were installed. The (3) internal clutches and all spider gears were deemed reusable.  Redline fluid added and the differential is now back in the car.

[jgerock]

Found some metal plugs at Home Depot that fit into the unused seat belt holes under the quarter windows.  I’ll paint them black so they don’t stand out so much.

[ray_]

5 hours ago, jgerock said:

Found some metal plugs at Home Depot that fit into the unused seat belt holes under the quarter windows.  I’ll paint them black so they don’t stand out so much.

You can paint Roundels on them.

 

😁

[Jam3422]

Jim - I'm curious about your "e21 spring washers installed" comment.  2002 LSDs don't use spring washers to preload the lockup, they use thrust washers of varying thicknesses for preload.  Preload, or breakaway torque is much lower on a 2002 LSD than an e21, they rely more on torque applied to the wheels for lockup.  Did Dave essentially convert your LSD to  an e21 type?  It never occurred to me that you could use the e21 spring washers in a 2002 LSD.  I've been fussing around with my LSD for a while, maybe I should go in this direction...

 

Thanks

[jgerock]

16 hours ago, Jam3422 said:

Jim - I'm curious about your "e21 spring washers installed" comment.  2002 LSDs don't use spring washers to preload the lockup, they use thrust washers of varying thicknesses for preload.  Preload, or breakaway torque is much lower on a 2002 LSD than an e21, they rely more on torque applied to the wheels for lockup.  Did Dave essentially convert your LSD to  an e21 type?  It never occurred to me that you could use the e21 spring washers in a 2002 LSD.  I've been fussing around with my LSD for a while, maybe I should go in this direction...

 

Thanks

You are correct.  Dave’s invoice includes this statement:

 

“Spring washer pair to convert from shims to E21-type LS carrier.”

 

 He recommended this to me when I contacted him via phone to discuss my rebuild.  This way, when the clutch discs start to wear, there will be pressure exerted on them.  
 

Jim

[Jam3422]

That's interesting, thanks for the reply.