Task No 5 dated 20th March 2018 Tuesday at Bhat’s Auto Care ( 9 am to 5 pm, 8 hours Task ) on my M - 800 DX car of 1998 Model at 55457 kms ( assumed figure since Odometer stopped ), in continuation to my task No 4 dated 16th March 2018.
I am giving the details for the benefit of all the members (I know there are many experts who are already aware of these points but this is for the members who are not experts like me).
I never realised that it takes so much of time for this Task of Gear Box Overhauling but it takes, that too for the 1st time in 20 years my Gear Box was opened. Mr Harish Bhat himself was present every now and then since Engine, Gear Box, Carburettor, Clutch and Brakes are important parts of Maruti 800 Car.
- Only the Left Side Wheel was removed on putting the Car on Jacks.
- The Battery was removed.
- Coolant was drained and Radiator was removed. The Coolant was clean
as I changed the coolant few months back only. I wanted the Radiator to be sent
for cleaning but Mr Bhat on inspection said there was no need as even the fins
were cleaner and I seldom travelled on muddy Roads and I do clean my car
regularly there was no over - heating issues in these 20 years. So Radiator and
Fan was cleaned with Air Jet.
- Gear Oil was drained and though it was clean, I asked them to throw and replace
it with new Gear Oil though it was changed at about 43000 kms ( for the 2nd Time)
Gear Oil lasts for about 30,000 km in Normal case as per Manual.
- The Starter Motor was removed and then the Gear Box by loosening some bolts,
cover plate and one Mount ( they call this as Clamp). The Mount was changed
since it had a small crack on rubbery thing.
- Since Gear Box was removed, Mr Bhat inspected the Engine Mounts and said
they are fine and no need to replace them. On earlier tasks, he had opened the
Cover of Engine and it was clean and said there was no need to change the
Engine oil so soon as the run was about 1500 km only, after the Engine oil Flush
was done and New Engine oil was put .He said for Mangalore hot climate 20W50
is the good , though he keeps 20W40, semi - synthetic and also fully synthetic
Engine Oil of all brands like Shell, Wurth etc.
- Clutch was inspected and was good since Clutch plate and cover assembly was
replaced in June 2015 at around 52000 kms along with Brake Flywheel and
Bearing Input shaft at MASS Mandovi, costing about Rs 3600 at that time.
- Also checked all the Boots of Drive Shafts, all are fine, no damage or any grease
leakage.
- This is just to inform that the Gear Box is SGP and not MGP and of course now a
days spares of Gear Box are MGP. It is Aluminium and shined after cleaning. All
the Gears were in good condition. So also all the Bearings since those bearings
were made in JAPAN. Grease was applied on all the Bearings. There are totally 4
bearings inside the Gear Box plus a Relief Bearing and one Bearing near the
cover. So there are totally 6 Bearings. All the 3 Oil seals were changed – 2 are
called drive shaft seals and another one is called top Gear seal. There are couple
of Dummy seals and they were fine.
- In this whole Task, the culprit was Speedometer Gear and wheel, which were
damaged and replaced ( MGP). However to fit these 2 items, the entire Gear Box
is to be opened, so I used this opportunity to get the Gear Box O/H done, though it
is an Expensive affair.
- The Speedo meter Cable that connects the Speedo meter and Left Side Wheel
was changed ( MGP), as the cable had become harder and also at the joint that
Connects at the LH side Wheel.
- Before Fitting back the gear Box, The AC condenser and the entire Engine Bay
was cleaned with Air Pet and whereas it possible, the little bit dust accumulation
was removed.
- 2 Litres of Wurth SAE 80w90 Gear Oil was put in the Gear Box.
- Since I had some remaining MGP coolant in the MGP can, Coolant was topped
up.
- On fitting everything and rechecking, we did go for a long drive on airport Road.
I drove the car and it was so smooth and like driving a New Car. Since the Road
was not having more traffic, after a long time I drove at a speed of 100 kms
(Normally I never drive above 60-65 kms at this old age) after 20 years which I
used to drive on Bombay – Pune Highway 20 years ago at the age of 51 years
and did the same now at the age of 71 years in this car. Thanks to
Prince of India Rahul Gandhi, as the Air port Road was empty and 2- 3 lakhs
Mangaloreans must had gone to Nehru Maiden to listen to his interesting speech
and free snacks and cool drinks.
Well, now the Interesting and Exciting point is :::: After the long drive and noting
down the initial Odo reading and filling up the petrol tank, what a Surprise:::: I got
18.3 KMPL after 4 years or so and hope it will pick up in coming days on regular
drive like this.
- The Cost aspects and no regrets as I am happy because Clutch has good play
now, Steering is so smooth and acts like a power steering, pick – up of speed is
very good, no vibration whatsoever. Even both the Rear Shock – Absorbers and
Rear Coil springs were changed recently, coasting about Rs 3000.
Total for the Spare Parts was Rs 1710, All are MGP except Gear Oil Wurth.
- Speedo meter Gear - Rs 45
- Speedo meter Wheel - Rs 120
- 2 Nos Drive shaft seals in the Gear Box – Rs 120
- 1 No Top Gear Seal - Rs 40
- Gear Box Mounting - Rs 480
- Speedo meter Cable - Rs 280
- 2 Lts Gear Oil = Rs 580
- Grease = Rs 45
- Labour Charges - Rs 1750
Total = Rs 1710 + Rs 1750 + Rs 200 Tips = Rs 3660
The next simple task are Wheel Alignment, which will be may be free at Wheel Care as I bought my 4 tyres recently from them and they give free service after 500 kms run.. Then go for Full Car Wash and also shampoo wash for Roof lining which may cost about Rs 600 – 700/
So the Grand Total from 14th March till 20th March 2018 :
Rs 1279 + Rs 1765 + Rs 520 + Rs 1000 + Rs 3660 = Rs 8224
May be another Rs 600 – 700 for Full Car wash and Cabin Roof cleaning.
Attaching the following Photos :
1 - Gear Box Removed.
2 - Gear Box Side View.
3 - Dismantling Gear Box.
4 - Gear Box Opening 1.
5 - Gear Box Opening 2.
6 - Gears and Gears Seals.
7 - Relief Bearing at the end of Gear Box.
8 - 1st Gear.
9 - Gear Cover is Good but Gear Mount damaged.
10 - Clutch Plate after removing Gear Box.
11 - Damaged Gear Mount to be Replaced.
12 - Engine Bay on removing Radiator, Battery, Gear Box and Starter Motor.
13 - Cleaning Radiator and Fan.
14 - Culprit 1 - Damaged Speedometer wheel.
15 - Culprit 2 - Damaged Speedometer Wheel and Speedometer Gear.
16 - Culprit 3 - Damaged Gear Seals.
17 - Gear Box Assembling after Cleaning.
18 - New Speedometer cable.
19 - Wurth Gear Oil - SAE 80W90.
20 - Part No of Gear Box Mount and Speedo meter Cable.
21 - Bill dated 20th March 2018.
