Project Slow Evolution
what is the world coming to 
03 March 2006, 12:17 AM
#93
03 March 2006, 07:27 PM
#94
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Once you have the box removed it should look a bit like this
Next task for me was removal of the standard clutch to reveal the somewhat worn flywheel.
A quick blast with the impact wrench sees this removed too.
A quick check over the rear crank shaft oil seal, and fortunatley its fine.
Just need to transfer the spigot bearing over to the new flywheel a lightened standard item. It should be about 7-8Kg, but when i tried to weigh it on the bathroom scales they just said error! They are the new fancy digital variety that wont weigh anything under 10KG
And the kitchen ones only weigh up to 5KG doh
So all i know for certain is its more than 5 and less than 10KG.
Next place the flywheel on the back of the crank and replace the bolts not forgeting the loctite.
Then line up the new exedy organic clutch and bolt in place.
Dont forget to remove clutch alignment tool
Clutch fork assembly and new release bearing fitted to the new box
New box on its way to it's new home.
Finally in place
Lastly put everything back on the car you took off and fill the box with oil.
I have over filled this one slightly using 4L of Castrol Syntrax.
Hopefully the pile of parts left over should not be too big
Next task for me was removal of the standard clutch to reveal the somewhat worn flywheel.
A quick blast with the impact wrench sees this removed too.
A quick check over the rear crank shaft oil seal, and fortunatley its fine.
Just need to transfer the spigot bearing over to the new flywheel a lightened standard item. It should be about 7-8Kg, but when i tried to weigh it on the bathroom scales they just said error! They are the new fancy digital variety that wont weigh anything under 10KG
And the kitchen ones only weigh up to 5KG doh
So all i know for certain is its more than 5 and less than 10KG.
Next place the flywheel on the back of the crank and replace the bolts not forgeting the loctite.
Then line up the new exedy organic clutch and bolt in place.
Dont forget to remove clutch alignment tool
Clutch fork assembly and new release bearing fitted to the new box
New box on its way to it's new home.
Finally in place
Lastly put everything back on the car you took off and fill the box with oil.
I have over filled this one slightly using 4L of Castrol Syntrax.
Hopefully the pile of parts left over should not be too big
03 March 2006, 07:38 PM
#96
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Since fitting the box i have covered about 250 miles in two days.
First impressions are that it is alot noisyer than standard, all the PPG gears do whine when engagaed and under load.
1st and 2nd create about the same noise, 3rd is the noisyest whilst 4th is almost as quiet as stock and 5th still being stock is as quiet as usual so mororway cruising is no problem.
Bear in mind my car has had no sound deadening material removed and the gear whine is quite audible in the cabin, however saying that if you listen to your stereo at any sort of reasonable level to compete with a full decat, then that drowns out the gear whine as well.
It will be interesting to see what i think about the gear whine after a few months living with it but at the moment it quite compliments the sucking noise form the turbo on WOT
Gear selection is nice and positive from the billet forks and i cant hear any rattleing from that department.
The exedy organic is nice to drive, if anything slightly lighter than the stock clutch which had lasted surpisingly well. It must be said that if you are quick with it, it dosnt half bite, something that standard clutch never really did.
Still getting used to the new bite point.
All in all a sucessful set of mods i think which will set me up for the next stage, im glad i did it myself, but i wouldn't want to be doing it again any time soon
only took me about 9hrs, not bad for a first go.
First impressions are that it is alot noisyer than standard, all the PPG gears do whine when engagaed and under load.
1st and 2nd create about the same noise, 3rd is the noisyest whilst 4th is almost as quiet as stock and 5th still being stock is as quiet as usual so mororway cruising is no problem.
Bear in mind my car has had no sound deadening material removed and the gear whine is quite audible in the cabin, however saying that if you listen to your stereo at any sort of reasonable level to compete with a full decat, then that drowns out the gear whine as well.
It will be interesting to see what i think about the gear whine after a few months living with it but at the moment it quite compliments the sucking noise form the turbo on WOT
Gear selection is nice and positive from the billet forks and i cant hear any rattleing from that department.
The exedy organic is nice to drive, if anything slightly lighter than the stock clutch which had lasted surpisingly well. It must be said that if you are quick with it, it dosnt half bite, something that standard clutch never really did.
Still getting used to the new bite point.
All in all a sucessful set of mods i think which will set me up for the next stage, im glad i did it myself, but i wouldn't want to be doing it again any time soon
only took me about 9hrs, not bad for a first go.
03 March 2006, 08:33 PM
#99
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Well i have another inlet manifold winging its way to me in the post at the moment curtosey of Daz Davies for the next part of the project. Watch this space.
Also going to pick up a small aussie gold box on monday
Also going to pick up a small aussie gold box on monday
03 March 2006, 08:46 PM
#100
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Nice one. Its even easier with a 2 poster (one of our best investments)
You had the car from new Danny? Curious as to why the blank for the gudgeon pin hole for no 3 is plastic.
(one of our best investments)You had the car from new Danny? Curious as to why the blank for the gudgeon pin hole for no 3 is plastic.
03 March 2006, 09:15 PM
#102
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Its looks like its had usual accountants treatment
I thought MY99 engines onwards had the metal plate covering the breather and gudgeon pin for no 3, not plastic.
I thought MY99 engines onwards had the metal plate covering the breather and gudgeon pin for no 3, not plastic.
03 March 2006, 10:51 PM
#104
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06 March 2006, 05:37 PM
#109
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New toy aquired second hand
Does anybody know where i can get hold of the right connectors for the M800, does RS or Farnell or someone like that stock them?
Also im after a dead 99/00 Ecu to butcher for its connectors to make an adaptor loom, dont fancy paying Motec prices
One of the many mappers out there must have a fried 99 ecu after a comms error?
I believe i have the MY99 standard pinout courtesy of one of simon's (JGM) threads on 22B, would just be in need of a base map for a 99 uk car to get it running once installed.
Does anybody know where i can get hold of the right connectors for the M800, does RS or Farnell or someone like that stock them?
Also im after a dead 99/00 Ecu to butcher for its connectors to make an adaptor loom, dont fancy paying Motec prices
One of the many mappers out there must have a fried 99 ecu after a comms error?
I believe i have the MY99 standard pinout courtesy of one of simon's (JGM) threads on 22B, would just be in need of a base map for a 99 uk car to get it running once installed.
06 March 2006, 06:57 PM
#110
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"Just need to transfer the spigot bearing over to the new flywheel a lightened standard item. It should be about 7-8Kg, but when i tried to weigh it on the bathroom scales they just said error! They are the new fancy digital variety that wont weigh anything under 10KG
And the kitchen ones only weigh up to 5KG doh
So all i know for certain is its more than 5 and less than 10KG."
Doooh !!! May I suggest you stand on the bathroom scales, note your weight, stand off, pick up flywheel, stand back on and calculate the difference between the two
And the kitchen ones only weigh up to 5KG doh
So all i know for certain is its more than 5 and less than 10KG."
Doooh !!! May I suggest you stand on the bathroom scales, note your weight, stand off, pick up flywheel, stand back on and calculate the difference between the two
09 April 2006, 07:15 PM
#112
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Just got back from a day out at Elvington, nice meeting some more names for the first time even though the weather was awful!
Good news for me though, i got another couple of runs in just before they ran the class finals when the track had dried out again, and i made another nice improvement from earlier in the day. New personal best's in quarter time and 60ft time.
Best effort today was 12.74 second qtr at 105mph, and 1.861 second 60ft
A marked improvement on my previous PB of 13.166.
Gearbox is feeling good, and im now getting used to the new clutch and flywheel, but iv'e still not got a launch that i would consider all hooked up properly yet.
The only thing thats bugging me is im getting a crunch between 2nd and 3rd with a high rev upshift. It never happens if i shift below 5K rpm but above it crunches, and yes the clutch is def in at the time and no crunches between the other gears. The box has Castrol Syntrax oil in it to the normal suabru fill level, im just wondering if a bit extra in might help matters?
Dan.
Good news for me though, i got another couple of runs in just before they ran the class finals when the track had dried out again, and i made another nice improvement from earlier in the day. New personal best's in quarter time and 60ft time.
Best effort today was 12.74 second qtr at 105mph, and 1.861 second 60ft
A marked improvement on my previous PB of 13.166.
Gearbox is feeling good, and im now getting used to the new clutch and flywheel, but iv'e still not got a launch that i would consider all hooked up properly yet.
The only thing thats bugging me is im getting a crunch between 2nd and 3rd with a high rev upshift. It never happens if i shift below 5K rpm but above it crunches, and yes the clutch is def in at the time and no crunches between the other gears. The box has Castrol Syntrax oil in it to the normal suabru fill level, im just wondering if a bit extra in might help matters?
Dan.
09 April 2006, 09:31 PM
#113
Danny
Good results for you, my best time was 13.01 @107mph with 2.01.. for the 60 ft. Still havent found a perfect launch, but not too bad considering its my first attempt at 1/4 mile racing.
Nice to meet you and also Graham for the second time.
Andy
Good results for you, my best time was 13.01 @107mph with 2.01.. for the 60 ft. Still havent found a perfect launch, but not too bad considering its my first attempt at 1/4 mile racing.
Nice to meet you and also Graham for the second time.
Andy
09 April 2006, 10:32 PM
#114
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Andy
You must have left before the class finals, it suddenly struck me about that time that you wanted to have a listen to the gearbox, but with all the chat going on it must have slipped our minds
I got those last two runs in at just the right time, a nice bit of luck for a change
Good times for a first outing
there is room for great improvement there i think.
You coming to scooby shootout?
Dan.
You must have left before the class finals, it suddenly struck me about that time that you wanted to have a listen to the gearbox, but with all the chat going on it must have slipped our minds
I got those last two runs in at just the right time, a nice bit of luck for a change
Good times for a first outing
there is room for great improvement there i think.You coming to scooby shootout?
Dan.
10 April 2006, 03:09 PM
#115
Originally Posted by Danny Boy
Andy
You must have left before the class finals, it suddenly struck me about that time that you wanted to have a listen to the gearbox, but with all the chat going on it must have slipped our minds
I got those last two runs in at just the right time, a nice bit of luck for a change
Good times for a first outing there is room for great improvement there i think.
You coming to scooby shootout?
Dan.
You must have left before the class finals, it suddenly struck me about that time that you wanted to have a listen to the gearbox, but with all the chat going on it must have slipped our minds
I got those last two runs in at just the right time, a nice bit of luck for a change
Good times for a first outing
there is room for great improvement there i think.You coming to scooby shootout?
Dan.
Andy
10 April 2006, 03:39 PM
#116
Originally Posted by Danny Boy
The only thing thats bugging me is im getting a crunch between 2nd and 3rd with a high rev upshift. It never happens if i shift below 5K rpm but above it crunches, and yes the clutch is def in at the time and no crunches between the other gears. The box has Castrol Syntrax oil in it to the normal suabru fill level, im just wondering if a bit extra in might help matters?
Dan.
Similar issues with mine. Also problems downshifting to 1st.
I forgot what oil is in mine but iirc its not Syntrax. Paul thinks that it 'may' be the oil. Will have to give that a go and see if there is a change.
Congrats on your personal best. Plenty more to come I'm sure
10 April 2006, 05:33 PM
#117
Thinking about the gears etc and crunching.
The synchro's have a lot more inertial to stop with the heavier gears and add thatto the 'fast' changes in competition and possibly thinner oil due to the torque/heat passing through the box, are the Synchro's up to it??
Just a thought.
Maybe a 6 speeder is better after all for a road/track car?
Graham
The synchro's have a lot more inertial to stop with the heavier gears and add thatto the 'fast' changes in competition and possibly thinner oil due to the torque/heat passing through the box, are the Synchro's up to it??
Just a thought.
Maybe a 6 speeder is better after all for a road/track car?
Graham
10 April 2006, 06:18 PM
#118
Dan, you know that turbo is capable of low twelves, so keep at it
Graham, other syncro'd ppg/par boxes in more powerful cars have been holding up very well...sounds like it could be oil related to me
Last edited by Tim W; 10 April 2006 at 06:20 PM.
10 April 2006, 06:29 PM
#119
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I have the same issue at the moment Tim, only in one gear, 3rd to 4th. 
BOB'5
Are you able to find out what oil you used as i'm thinking of changing mine to see if anything improves.
BOB'5
Are you able to find out what oil you used as i'm thinking of changing mine to see if anything improves.
Last edited by AlanG; 10 April 2006 at 06:46 PM.