Thread: D5 (2005 on) - Swirl Chamber operating arm
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Old May 20th, 2010, 15:18   #28
jonesys60
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Last Online: May 25th, 2011 21:40
Join Date: Jul 2008
Location: Bicester
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I also have the same problem with my 55 plate 2.4D, which to be honest I'm not especially happy about as the design is very poor.
Anyway, I am going to do the same as bic1 with the bracket acting as a bump stop, but in the meantime I decided to do a temporary repair that seems to be holding up fine and is pretty simple.
Essentially it is the same method as has been mentioned on numerous occasions on the forum, but instead of attempting to drill the 'lever' part of the mechanism on the engine, instead I took a 2mm nail and heated it to red hot and passed it through the plastic lever (on the engine) as centrally as possible to where the ball joint fits inside the cup.
I then drilled a 2mm hole through the ball joint end of the arm and fitted a 1.5mm split pin through both parts and carefully splayed the end of the pin. One thing I did have to do in addition is flatten the head of the split pin as it fouled the alloy of the head when it retracted.
This literally took me about 15 minutes to do and so far has held up fine.
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