Probably only Dr Bert may know this..

I am putting my front pump together on my 722.120 transmission (4-bolt) and I am tightening the four bolts that hold the front cover of the pump against the back of the bellhousing. The ATSG manual says to torque them to 15 ft lbs and the pump should still turn freely. When I put more than 2 or so pounds on them the pump binds. What could be wrong? The pump's innards look fine and I have lubed it with fluid.

Rick

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80 300SD (129k mi) 82 240D stick (193k mi)77 240D auto - stick to be (153k mi) 85 380SL (145k mi) 89 BMW 535i 82 Diesel Rabbit Pickup (374k mi) 91 Jetta IDI Diesel (155k mi) 81 VW Rabbit Convertible Diesel 70 Triumph Spitfire Mk III (63kmi)66 Triumph TR4a IRS (90k mi)67 Ford F-100 (??)

Most likely, you will find a very small burr or chip of metal in the pump housing. This is a very common problem. Clean it twice and then clean it again.

Run a small screwdriver along the oter radius (corners) where the big gear rests. I have pulled small chips of metal out of there that were hard to see with the naked eye. It will definitely cause the pump gears to bind up.

If you are still having trouble, call me Sunday between 11:00am and 10:00pm PST at (559) 967-1162.

Good luck...Bert

Just to bring this thread to a conclusion....

After consultation with Dr. Bert and some discussion of the finer points of the 722.1xx ATSG manual (including the fact that nowhere is it mentioned that all measurements are metric, for example) it was determined that a crucial fact was omitted from the manual. The manual says that the pump should "turn freely" after the bolts are torqued to about 15 ft lbs. I assumed that meant that if one inserted a screwdriver in the slot of the front pump, it would turn freely. Apparently, that statement assumes that you have some sort of mandrel that simulates the end of the torque converter, because if you try to turn the gear with a screwdriver the gear binds and you think you have grit in the pump. I set the torque converter on the bench and spun the pump with bellhousing above it. In that configuation, the pump was fine.

Many thanks to herr Doktor for his guidance in this matter.

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80 300SD (129k mi) 82 240D stick (193k mi)77 240D auto - stick to be (153k mi) 85 380SL (145k mi) 89 BMW 535i 82 Diesel Rabbit Pickup (374k mi) 91 Jetta IDI Diesel (155k mi) 81 VW Rabbit Convertible Diesel 70 Triumph Spitfire Mk III (63kmi)66 Triumph TR4a IRS (90k mi)67 Ford F-100 (??)

I am glad to help, Rick.....

I don't know everything about these cars, but I am always willing to share what I do know with others.

Let me know how your end clearance turns out.

By the way....thanks for the photos of the Transmission Modulator Valve/Hoses on the Injektion Pump. My car is a 1978 116.120 and it is light years different than the engine in thos photos. Mine has nothing up on top the valve cover but levers...Bert

Rick,

How did the end clearance work out on that 722???...Bert

Bert-
Haven't done the end clearance yet. Were you able to get a better handle on what the nominal spec clearance should be?

Did you need any more pictures? That's a 1980 California 116.120 in the pix I sent you.

Rick

__________________
80 300SD (129k mi) 82 240D stick (193k mi)77 240D auto - stick to be (153k mi) 85 380SL (145k mi) 89 BMW 535i 82 Diesel Rabbit Pickup (374k mi) 91 Jetta IDI Diesel (155k mi) 81 VW Rabbit Convertible Diesel 70 Triumph Spitfire Mk III (63kmi)66 Triumph TR4a IRS (90k mi)67 Ford F-100 (??)

Pictures were great, but way different from the setup on my 1978 116.120. No worries though, I figured it out finally.

Will work on end clearance for you this week...Bert