 Most viewed - How-to |
395 viewsNew fog-light equipped light switch. To operate simply push the dial in. Of course, you have to go to the *&$%! dealership to get it 'enabled'! Fogs automatically turn off when high beams are turned on, however, they remain on when using the "flash to pass" feature. Also, the 'system' remembers the position of the fogs so if you leave them on when you turn off the lights, they will automatically come back on when you turn the lights back on, including if you turn off the car.
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394 viewsThe repaired pin in place. Thin plastic washer goes between the gear (front and rear gears) and the case.
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Getting the power ready for the turn signal LED array.393 viewsUse a BLUE wire tap-in like what I show. The ones that are RED are for smaller wire sizes and the YELLOW ones are for larger wires. I prefer these because when you insert the insulated male connector it makes a positive fit and keeps the tap locked on to the wire. -- Left side: Tap into the white wire with the GREEN stripe. -- Right side: Tap into the white wire with the BROWN stripe. -- FYI for both lights: The black wire [on the outside] is ground, the middle wire is the parking light and the other outside wire is the turn signal.
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392 viewsTop view of LEDs firing.
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Connecting the DRL LED array.388 viewsI used a hand drill with a 2mm drill bit (smallest I had) to carefully drill a pilot hole into the side of the relay box. The pilot hole is 7mm down from the top of the lip of the fuse/relay box. It's between fuses M20 and M27.
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387 viewsThis picture and the next show that the corner is cut and folded onto itself. It's best to have over-lapping than a gap in the insulation.
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387 views
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384 views
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383 viewsHere's the VR (voltage regulator) information. This is what you need. I got mine for $3.15 at Norvac Electronics, Inc. You can also get it at Fry's. NTE1932, IC voltage regulator, positive 10-volts, 1-amp.
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383 viewsWhere I zip-tied the left side of the harness. It comes down near the radiator over-flow container (the pink bottle). Don't use the aluminum object to the left, that's the heat-sink for the coils!
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383 viewsPermatex 2A gasket silicone is what I smeared on the mating surfaces of the case half instead of using a gasket.
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382 viewsThe new pin in the hole, ready for welding.
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381 viewsThe pin is missing. Looks melted...??? Without this pin set in the case halves the planetary ring rotates and doesn't allow the forward gear to rotate properly.
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Reference: Rear gear box, front side.380 viewsFront side of rear gear box. Steel roll pin is 3/16" x 1-1/4". This is where the drive shaft fits.
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377 viewsAll the bearings are roller bearings and they are held in with the grease. When cleaning the grease and wiping the bearings they will most likely fall out so work over a soft, plush towel to keep them from bouncing away. Pack the bearings and cage surfaces with fresh grease and slip any fallen bearings back in. You should see no gaps between the bearings. Pack more grease in when they're all in and roll them around with your finger to spread the fresh grease around. It will hold them in there.
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377 viewsSame thing for forward gear.
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376 viewsShowing the path of the LED array as it goes down on the front part of the head light. That blue thing is simply a nylon auto trim tool I had laying nearby that I used to hold the fascia away from the head light so I could work with both hands. Now just apply power from the turn signal tap!
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375 viewsInside of rearward gear and planetary gear mating teeth.
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374 viewsFlap fully open, allowing some of the heated air to divert into the center of the Bus for the rear passengers.
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374 viewsNext, I used a 15/64" (almost 6mm which would work fine) and hand drilled the hole for the grommet (yes, I twisted it with my bare fingers). I wanted to make sure I drilled straight and using a hand-held drill would've caused the hole to be at a slight angle due to the head light housing interfering with the drill chuck.
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