Now your gearbox should be in this position OUT of the car



Next installment tomorrow.

 

What's this? Proper tools being used to support the engine rather than a strategicly placed block of wood what is the world coming to

 

For the princley sum of 60 quid for the rental of the workshop for the day, it would be rude not to

 

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

 

Ace!
Graham

 

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.

 

Graham if you want a go as an assesment you only have to ask

 

*rubs hands together* So whats next Danny

 

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

 

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.

 

Not had it from new, bought her at 3 years old from an accountant!

 

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.

 

Danny, thank you for the offer, you may well get a 'call' in the year when mine pops.

Graham

 

Metal on my 00.
http://www.ashlyn.plus.com/projects/...lessengine.jpg

 

Hmm, seems that they cant make their mind up what to put in!

 

Got to be a few gramms of weight saving there

 

Or its had an engine rebuild, and someone put the wrong bit on

 

We'll find out when i blow it up

 

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.

 

"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

 

DOH, should have thought of that.
Not thinking straight after 14hr flight back from HK.

 

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.

 

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

 

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.

 

Yes I hope to, I will be applying this week

Andy

 

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

 

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

 

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

 

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.

 

Not the detent then...bugger