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Panda (Classic) Axel the Sisley 4x4

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Introduction

Hi All, as you may be aware I purchased a certain Sisley 4x4 from @onemanmade a week ago.

It was a long (ish) trip up north of the boarder but well worth the trip!

We made it back without too many hitches, first problem was I brimmed the tank and subsequently lost several liters after it seemed to just come straight out the top of the tank. Don't know if something hasn't been fitted correctly after the tank was taken off or I did try to squeeze a little too much in causing it to come out the over flow :p Second issue found on our way back was as well as the clutch bearing being noisy (which we knew of) the clutch is slipping big time, you can accelerate if you do it carefully but if you just plant your foot the engine just revs and the clutch disengages.

Anyhoo I knew it would be a rolling project and the fact its had all the welding done means its a very good place to start :)

So lets crack on with some pictures!

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Meeko also had to inspect, she approves

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So a 'To Do' list is in order:
Clutch
Fan switch mod
Lift Kit
Swap bull bars
Roof Rack
Plumb in the CB
Second set of wheels (with chunky offroad tyres)
A spare numberplate for our trailer!
Investigate Fuel tank
Investigate Temperature issue
Adjust Handbrake

PS: Some of you may have noticed I have changed the name! Can anyone guess my theme yet?
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andyholli said:
Petrol leaking from tank on fill up... Yes, I think something like this has happened to me - you need an AndyPanda4x4 to take the weight of the tank (it's okay to leave it full) while you reattach the breather pipe.
- Doable in a car park.
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It's even doable wearing a boiler suit in +30 degree heat surrounded by other Panda enthusiasts at the side of a football pitch ;)

Oh and I like the fact that's also "okay to leave it full" Andy!! :)
 
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So, I've been purchasing some items for our little clutch replacement at the weekend and have bought the following parts:

Clutch Kit
Engine Mounts
Clutch Cable
Manifold gasket

Can anyone think of anything else I could buy?
andyholli mentioned a gearbox input shaft seal but I'm unsure if this is the correct part:

Seal.PNG
 
I've done clutch on the Black one about 3 years ago, engine was still in - but well supported on DIY crossbeams. As engine guard bolts are still fresh should be easy to undo them.

Nice access to flywheel and g/b input shaft seal. While youre there, have a good look on the crankshaft seal as well as clutch lever top plastic bush.
Inspect flywheel for small centrifugal cracks.

gearbox_out.jpg
 
My old Sisley used to leak fuel above half full - when I got the tank out I saw it has corroded all round the centre seam - hopefully yours isn't as serious!
 
ally4x4 said:
My old Sisley used to leak fuel above half full - when I got the tank out I saw it has corroded all round the centre seam - hopefully yours isn't as serious!
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I can't imagine that. The previous owner who has a thread up here (it was called Englebert) had stripped the fuel tank and refurbished it. There are pics in the thread.
 
Here are some pics from this weekends work at Toretto's Garage:

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So clutch replaced. Managed to replace the outer gearbox seal but didn't manage to do the bearing behind it. Managed to swap both engine mounts too.

Seem to have an earth issue however. Starter doesn't appear to start the engine every time. It just clicks, a couple of tries later and fires up fine. Also got the battery warning light coming on. We've checked the earths and also replaced the negative lead from the battery. We also replaced the alternator but still comes on (albeit much dimmer than before). Anyone got any idea's?

PS Many Many thanks to AndyPanda4x4 for his fantastic help this weekend!
 
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Freebo said:
Starter doesn't appear to start the engine every time. It just clicks, a couple of tries later and fires up fine. Also got the battery warning light coming on. We've checked the earths and also replaced the negative lead from the battery. We also replaced the alternator but still comes on (albeit much dimmer than before). Anyone got any idea's?
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Have you swapped the battery for a good known working one, the amount of times I've known starting issues with starter motor clicking etc and it just turns out the battery is on its last legs, often it'll output normal voltage but can be knackered. If you haven't already I'd definitely try another good battery on it to see if it solves the issues (y)
 
Didge3 said:
Have you swapped the battery for a good known working one, the amount of times I've known starting issues with starter motor clicking etc and it just turns out the battery is on its last legs, often it'll output normal voltage but can be knackered. If you haven't already I'd definitely try another good battery on it to see if it solves the issues (y)
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Yes we replaced the battery, it was on a 34mah battery but is now on a known working 45mah battery.
 
Been looking at replacement starter motors and altenators this lunch time to try and resolve the battery/starting problem.

I have found a new starter easy enough but struggling to find an Altenator, I have two part numbers 7565832 which appears to be an old PN and brigns up rather expensive altenators and 5999868 which brings up some but only in the 'More Items related' section of the search on ebay.

For example, this one: http://www.ebay.co.uk/itm/310618889056, has the PN listed but doesnt have the 999 4x4 or the 1000 4x4 as a compatible match. It is however 12v 45amp which I belive to be correct. Would this alternator be the one im after?
 
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any alternator from any 8v FIRE engine will fit.. the only 2 differences will be the pulley being a multi V belt or single V belt, and the electrical connectors on the back requiring a slightly larger eye crimp connector.

remember my alternator upgrade i did to Talon? 95 amps from the puny 45 amp alternator i had before.

you can skip the part where it took it all to bits, the only bit you would have to do is change that multi V belt pulley over to a single V belt pulley.

though i do think that it would be better if you just replaced the bottom engine crank
pulley over to a multi V belt and just use that. i know if talon has not been ran for a while and the rear battery is completely (or near enough) flat it does squeal like mad on the old single V belt.
 
Sounds pretty familiar to me
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Meter probe was attached to cylinder head next to temp sensor, car left on idle. 87.4*C when the fan kicked in.

As long as rad fan kick in at some point it's fine and safe to drive.
When we reached top of Passo Di Stelvio pointer was touching red mark, wierd felling and hard to ignore when your other pandas shows correct temp.
 
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