E-Z out, auto to manual conversion

[Mike Arman <armanmik@n-jcenter.com>]

For our lister with the broken bleeder screw, yes, an E-Z-out is the item
you want. This is best done on a bench so you can hold the caliper where
you can get at it. Using a new, sharp drill bit, drill directly into the
broken-off screw. Tap -don't hammer- but do tap the E-Z out into place, and
unscrew the broken screw. Heat and penetrating oil first often helps. Trick
is to drill the screw so there's not much metal left of the screw, but
enough for the E-Z out to grip.

What often happens is that the remaining bits crumble, and then you get to
pick it out bit by bit. This is not as nasty a job as it sounds. Only catch
is that the E-Z out is NOT used to break the stuck bolt loose - that WON'T
work . . . but rather to remove the headless end down in the hole
somewhere. The heat and penetrating oil will help break it loose, as will
drilling it out, which relaxes the bolt somewhat by pre-removing most of it.

Stripping and rebuilding the caliper is a good idea, too - you want to get
all the bits of crud out.

I did a pair or rear calipers (38mm Girling) last week from a low miles 89
100. You wouldn't believe the CRAP that was inside of them - and they were
working fine when removed. Coupla tricks on those, too!

Automatic to manual conversion on 87 100 CD - need tranny (obviously),
clutch and flywheel, clutch master & brake cyls, hose, clutch pedal
assembly (which hangs from under the dash - lots of sheet-metal bits and
bolts), possibly brake cylinder reservoir (has outlet for clutch master),
and both half-shafts (different between 5 spd & automatic). Engine is the
same.

This is NOT a trivial job - probably the best way to do this is to find a
wrecked 87 5 speed and buy the whole car, taking all the bits you need. If
you do this by buying from a parts yard, you'll wear a groove in the road
going back and forth for one tiny part after another which you'll need to
finally finish the job.

Did you get any quotes on repairing/rebuilding the autotranny you have? I'm
under the impression that these older units are actually the old type III
VW autobox in disguise, and those are not particularly tough to find parts
for or rebuild.

Anyone have some specs on the N/A 2.5 liter Eurovan motor? Is this the same
as our 2.3 N/A engine? Could it bolt into our cars? Any point to this?

Best Regards,

Mike Arman