ARO Restoration

[Geo7]

Hi from a newbie in Greece.

I just found the forum and I find it really nice.You have done a great job! I am starting a restoration of my ARO 240 mod 78. I would like to know if the Toyota 2L 2,4 litre engine fits in the gearbox. Currently the engine is the Romanian diesel, capacity 2,5 liters. What kind of modifications are needed and if are there any photos to help me out.I plan to change the brake and the clutch pump, as well as to install power steering. But it is really difficult for me to find spares here in Greece. Where I can find any spares?
Keep up whith this great thing!

Thanks in advance,
George

[Werner]

Hi!

I think it is easyer to buy some spare parts for Your ARO. To fit a Tooyta engine it's dificult. If the engine is to powerfull, Your gear box will die very soon. The old break system is good if You have a good master break cylinder. Some ARO owners in Germany change the original master break cylinder whit one of VW Golf 3. I will ask one of them, maybe he have some pictures.
What parts You need? Maybe I can help You. If it's the original Diesel Engine, it's a 2,7L engine, exactly 2660 ccm.

[Geo7]

Hi again,

thank you for your reply. regarding the engine it has the peugeot 2.5 XD3 engine , which is about 70 ps and the Toyota engine is 72 to 87 ps. Do you think that amount of increase will be significant? Of course the old gear box will be refurbished. I am concerned if the toyota engine matches to the gearbox. This engine, anyway was installed in one version of the 24 series.Any ideas accepted!

thanks again,
George.

[Geo7]

Also, I need to change all the wheel cylinders and install a powersteering.Does anyone know which one is easy to be fitted?

[Ramiro]

Welcome George

If I had to replace the brake, clutch pump, wheel cylinders and install a powersteering of an 78 Aro 240, I will certainly prefer the original spare parts that are relatively easy to find in Romania instead of adapting other 4x4 parts, such as Toyota, because that solution will bring you even more problems in the near future.
Believe me. I know what I'm talking about...

Regards

[OstrongAudio]

Hello George!

Since a few month I´m restoration a ARO 244 from 1976 and I was driving a ARO 240 also from 1976 since few years as every day car, also with our new born doughter my wife drove the 30+ years old ARO 240.

Why do you need powersteering? My wife has driven the ARO 240 about 20000km in the last years and she didnt needed any powersteering (and she is no bodybuilder). Also in the 244 there will be no power steering and the 244 will be the familiy car.

If you have a XD3 engine you can buy a turbo loader and the fitting exhaust from XD3T (sometimes on ebay and their is also a german Indenor dealer who should have this parts) and your engine will have about 92-95 which will be quit much for the gearing box and the syncronrings.
Do you have the old or the new syncronrings for the 3 and 4 gear?

Why do you need to exchange all wheel brake cylinder? You can clean them an fit new sealings into them. If you have the old 2-screw wheel brake cylinder they are very hard to get and if you get one it is a "new old stock" with more rust inside than the used ones. I have many experience with "new old stock" against repaired used cylinder and everytime the used cylinder with new sealings are better.

Both, the clutch pump and the clutch cylinder have the same sealings like the wheel cylinder, just insert new sealings. Some yeas ago I have bought a "new old stock" clutch cylinder and it leak, I insert a new sealing in the "new old stock" clutch cylinder and it also leak. Then I took the new sealing and insert it in the old clutch cylinder and it is working since 5-6 years now.

In my hands I had about 80% of all ARO 24 parts (exept engine) and allways it was better to repair the old parts than buying new ones. The first steering rubber lastet 30 years in my ARO 240, the new steering rubber on my ARO 244 lastet 3 years (in the 3 years the car was 99% in my garage waiting for repair, it drove 0km and the rubber was dead!!!).

Greetings
David

[tudop]

There is a version of XD3T engine with intercooler that develops more than 100Hp, you can even buy a complete Peugeot from France (~500euro) and extract the engine.
You can also use disc brakes from Suzuki, but there will be some custom parts to manufacture. Power steering can be adapted from old series 5 BMW's

Where do you live in Greece?

[Werner]

You can reply Your engione, whit a Peugeot Turbo engine, You find it in DAF 440 series, it's the same like in ARO. If the brake cilinders are ok, i can send You the rubber gaskets for master brake cylinder, wheel brake cylinders, and the rubber gaskets for the other cylinders.

[Maxim]

It already was said, but no difficult to replay
repair kit for the clutch slave cylinder - D3210
repair kit for the wheel brake cylinder - D3199,
all from Seinsa autofren (Spain), buyed in internet-shops,
cost ~ 5 E for one kit.
About clutch and brake master cylinders I'm will say short while later.
I will not argue the benefit powersteering - it is undeniable, especially, in a metropolis, and frequent, and long trips (I know what I'm saying).
Full description of the process about the powersteering fitting:
http://www.offroadclubaro.com/viewtopic.php?f=14&t=303
it not axioma, it one from way...
best wishes, Maxim.

[Maxim]

-----Clutch cylinders-----

Probably, just replace only of the master cylinder, or, only of the slave cylinder, is not possible.
The reason for this:
Diameter master cylinder ARO - 25mm, slave cylinder - 32mm, the ratio (gain) - 32 / 25 = 1.28.
The vast majority of the master cylinders, not ARO, has a diameter - 3 / 4 ' or 19.05mm, at least 13/16' (20.6 mm). Gear ratio will be 32/19 = 1.7. This is much larger than the original. The pedal will is very" easy ", but can not enough pedal stroke to actuate the clutch.
Output, in this situation - to change the master and slave cylinders "in sets". Use the kit can be from different models and even different brands of cars.
Typical dimensions (inner diameter) of the slave cylinders:
3 / 4' = 19.05 mm
13/16' = 20.6 mm
7 / 8' = 22.2 mm
15/16' = 23.6 mm
1' = 25.4 mm
Even in version - the master of the 3 /4' , slave 1', the ratio will be 1.3 (3)
that is a realistic value.
Replacing only of the slave cylinder a possible on dimension 1' or more.
Otherwise (if the diameter is less than 1') it will be "hard pedal" and difficulty in managing the "dosing pedal clicking", ie "harsh and stiff pedal."
good luck.

[Geo7]

Hi again,

Thank you people for replying. i was out for a few days and my reply is a little late. also i stay far from the aro and my father -as an engineer- has to do all the checks, so it takes time..
as far as i concern if the cylinders are ok, i will change the repair kits on the cylinders, and will find a servo to fit in the space. i am thinking of doing the land cruiser pattern for the power steering- thanks everybody.As soon as i have news concerning the sealings i will inform you. I live in Athens, so I suppose shipping is easy. Thank you everybody for your help, enjoy your ARO's!

Greedings from Greece!

[Ramiro]

Hi, George

After the restoration, we would appreciate if you post some pictures of your Aro 240 mod 78, and tell us more about its history. An Aro with Greek number plate is a rare curiosity.

[Geo7]

Hi again, people!

I found out that the brake drums are ok, but when the car was working, as soon as it was hot, the brakes did stuck because of the high temp. How can this be solved? Does it worth it, or do I need to change the front ends?

[UMMM461]

Dear Geo7

Aro vas manufactured with toyota 22RE (petrol) and 2LT-2 (disel) for sure you can use a 22r or 2LT engine. Only thing I do not knoow is if there are ani changhes to the gearboz for the toyota engine.
Regards

[Geo7]

Hi again!

Thank you very much for the reply. I am considering to change to a 2l Toyota diesel engine, due to its reliability. Anyway, my current concern is that the brakes got hot and I have to solve this first.

Many thanks!