Bulkhead & Dashboard Removal

Good morning all!

Can anyone direct me to a thread showing the steps to strip and remove a 300Tdi bulkhead and windscreen, including dashboard removal? I assume this has been covered but having trouble finding the right thread.

If there is also a thread showing how to refit bulkhead and windscreen and reassemble that will no doubt be very useful!

Thanks in advance.

Ive just done some major work on the bulkhead on my TD5 last weekend. I just repaired mine and didnt take the whole thing off, but for what its worth I would say this;

• Window frame removal refit - Headliner needs to come off, 3 bolts on the bulkhead either side, 1 screw either side above the door frame and about 5 or 6 bolts above the windscreen. The bulkhead has 2 pins just above the vents which the frame locates into. Window wipers need unbolting and pushing thru the dash (one is right infront of the actual air vent so this needs moving). My bulkhead flexed enough just to allow the frame to move and it just popped out from the top first. Easiest part of the job. refit was actually a doddle, obviously its sensible to fit a new seal ( there are two types - - bought both and Im glad I did)
• Dash is simple to remove - 3 small stumpy screws on the top of the dash, 6 holding the vents, grab hand, and the instrument binnacle - really easy
• While you're doing all this it makes sense to replace the door hinges. I would also replace the hardware inside the bulkhead - dont go for the standard clips, they will just make you go mad, get the ones that have the nut welded on
• I replaced the footwells about a year abo and didnt need to remove the bulkhead to do this, I just removed the wings, which was really easy to do and gave full access. Replacement panels are plentiful and easy to weld in. I tiger sealed everything afterwards
• Get good quality panels - I got mine from YRM and they were perfect
• Replace all bolts etc with new
• However underpinning all of this is the appreciation that its going to take time -I did mine on a Friday evening and all day Saturday and I was exhausted!

Hope this helps

Regards

Stumpy