W163 ML270 2002 722.6 won't engage any gears!

[Arudge]

No Andy I use a solid steel insert engineered by a guy selling on eBay ...and to be honest you're not really drilling solid material...just the existing threads .. So you drill out either 8mm if you want it to bite heavier into the head or max 8.5mm if you want it to glide in a little easier..drill between 30mm to 40mm deep. I drill 8mm ... And about 35mm deep...you have to be careful how deep as there is a coolant gallery directly below the injector bolts...but you simply measure the existing hole depth and don't exceed that...but no need to go to original depth anyway..The insert comes complete with a high tensile shouldered hex bolt...so when you tighten down the injector you are bolting into steel not aluminium and it's not a stretch bolt....can be reused also.... The guy I think charges £15 delivered each... Comes with a little undersized sleeve so you use the bolt to wind in the insert ... I loctite the insert too...then simply wind the bolt back out and install injector.
This is the item in the photo

Excellent. I've no idea what Loctite your using, but if the Loctite fails i can highly recommend Loctite 638 retaining compound. We us it as a thread retainer in very aggressive applications, you'll need oxy acetylene to get the thread back out again!!

 

[Blueyes1971]

Ok so here's what arrived this morning from JPAT... both inner and outer pump cogs.. they didn't have them so the sourced them, got them same day, sent them same day and arrived to me less than 24hrs later.
The most helpful, understanding, positive and proactive companies / staff I have dealt with in many years.
A huge shout out to them... packaging was insane and left nothing to chance...
Time to install .. reassemble and refit.

 

[Blueyes1971]

Excellent. I've no idea what Loctite your using, but if the Loctite fails i can highly recommend Loctite 638 retaining compound. We us it as a thread retainer in very aggressive applications, you'll need oxy acetylene to get the thread back out again!!

To be honest Andy, you don't need loctite really these will never come out due to the low torque and the bolt doesn't reach the bottom anyway due to the clamp.. but I like to over engineer for security and peace of mind... you only really drill just longer than the insert to make sure you can get it down flush at least.. don't want it proud and not be able to take it back out to drill further .. you just won't get it out

 

[Blueyes1971]

Ok.. pump cogs installed, greased, o ring oiled on inner side but on the outer side I added clear rtv I use for crank cases.. slipped on sweet .. torqued bolts to just over 15 ft lbs and sealed the lip with more clear rtv.
Just wanted to make sure no leaks into bell housing.. I do not want to remove trans right away for a pump leak
Next!

 

[LostKiwi]

Be very careful using RTV as any excess that squeezes out of the joints can break off and block galleries.

 

[Blueyes1971]

Good point Kiwi
Completely agree...I guess I'm taking it for granted everyone knows ..cleanliness is key here.
So that said...I'm only using it very sparingly or carefully around any galleries...but mostly only on the dirty side of joints where there is no possibility of contamination.
The only other place I'm using it is on the bell housing to main case bolts...just under the heads so no chance of bolt leak...pic to follow just torquing them down.

 

[Blueyes1971]

Ok... bell housing to main case bolts installed with loctite and rtv... main shaft free and all good... brake cleaned the casing .. dipstick seat and connector plate socket seat .. ready for valve body installation

 

[Blueyes1971]

Valve body, connector plate socket and filter installed

 

[LostKiwi]

Valve body, connector plate socket and filter installed

Going well!

 

[Blueyes1971]

Pan with new gasket along with bell housing inspection gromnets installed... jus the oil cooler pipes to go for now as I'll fit the dipstick tube once it's bolted to block...

 

[Blueyes1971]

Ok there she is... ready to accept the TC when it's under the car so that's it for today... I've got rehearsal but not back to work until nightshift tomorrow so will begin the install in the morning.
Watch this space

 

[LostKiwi]

Well done! Fingers crossed for tomorrow...

 

[Blueyes1971]

Well done! Fingers crossed for tomorrow...

Thanks Kiwi... And my toes

 

[Arudge]

Back home now after a remarkably uneventful journey home, wishing you the very best for tomorrow, i know how much of a struggle it's going to be.

 

[Blueyes1971]

Back home now after a remarkably uneventful journey home, wishing you the very best for tomorrow, i know how much of a struggle it's going to be.

I'm confident it will go smoothly to be honest Andy...staying positive...just about to get the trans under the car and get TC on it...then the only awkward part is balancing it all on one jack on my back...operating the jack one handed while steadying with the other...once its close I'm sure I'll be able to man handle it on...we'll see....will report back once it's up.
Here we go

 

[LostKiwi]

Good luck and be careful!

 

[Blueyes1971]

It begins

 

[Uncle Benz]

Are you sure that's full home? Probably the angle of the picture, but looks a little far out still to me

 

[LostKiwi]

Make sure the TC is fully located in the oil pump!

 

[Blueyes1971]

It is for sure thanks guys