326 replies to this topic

[apbellamy]

The van came out of it's winter hibernation today. Battery is deader than Elvis, so with a quick jump start it fired straight up (once I'd turned the fuel pump on ).

I've pulled apart it's 'new' straight cut box. It's pretty obvious why the case broke through the diff housing.



There was no shim on the main bearing carrier, leaving the double roller looking like this:



Lay gear thrust washers where slightly worn...



The oil pick up was holed and covered in crap.



Obviously who ever built it didn't have a clue!. The gear set seems good, synchros are in good order. So it should build nicely into a new case (using all new bearings and thrust washers).

[John H]

They are far too shiney for such a clapped out old shed!

Clapped out old shed!

Tell you what race you at Avon!

Edited by John H, 12 February 2011 - 08:52 PM.

[apbellamy]

We did a little bit of disassembly last night.






The bores are all lovely and the pistons don't look to have suffered any detonation related damage. The head gasket was spot on too. Not bad for a bit of home brew tuning.



We also did one more really important job - fitted the new wheel centres.

[apbellamy]

I've snapped another flywheel puller.... Got the box of the block and did a little bit of disassembly.

So... what does 150 bananas, plenty of emergency starts and a load of abuse do to a randomly chosen unknown standard box?




We reckon a few more miles and we'd be picking teeth out of the sump.

[MRA]

If you need the stronger rear "TURBO" engine mount bracket I still have one in my parts bin, it is the one under the brake / clutch master cylinder and is considerably thicker than the standard version.

Also PM me if interested in a layshaft that is stronger than any other on the market by far.

[apbellamy]

Any pictures of the bracket? I didn't think they where any different???

As long as the bearings are OK then I can't see a need for a stronger lay shaft...

[John H]

Is this the shaft you are talking about Martin?

This one???

[MRA]

No John, that is just our normal hi specification..... top of the range for others.....

The one in the link is the one on the left of the photo and is an A+ type (3 step).....

The third from left is an A series (2 step)......

The one I am talking about is the second from left layshaft in the photo....

And yes the case does need to be machined to accept it and yes we have the tooling to do so

If yo uhave ever wondered what the "scuff" marks are on the area just under the bearings, it is mainly caused by the layshaft flexing... never seen it ? then you haven't got enough power or torque to worry about it and this mod is not for you

[apbellamy]

We did some cooking the other night...




All new bearings in the transfer case and box. Just need to get a few more bearings and thrusts and clean the gear set up and it can go back together.





Had a tinker today and got the new intercooler sorted (rad is just chucked in atm). Hopefully it will be an improvement over the last setup.

[MRA]

Any pictures of the bracket? I didn't think they where any different???

As long as the bearings are OK then I can't see a need for a stronger lay shaft...

No sorry no pictures, but they are a fair bit thicker

[apbellamy]

Got the old zaust of this morning and worked out how I'm going to run the new one.



Then I dropped the old gearbox back in and refitted the new intercooler and rad. All the pipework seems to route well and clear everything. Much tidier than the last setup. )




Plenty of room for a second smaller rad fan. I may run that one constantly and have it on a timed relay along with a small pump to circulate coolant through the turbo after shutdown.

[apbellamy]

Been trying to get the new turbo mounted up on the manifold. Lots of fire and swearing later, the studs are still in the housing. Will have to try that again another day. Did a bit of porting on the manifold.






Then pulled the dash out and junked, the heater, pipework and sound deadening.



Then made something a bit lighter to go in it's place.

[mini_mad69]

Very nice.

What's the intercooler off?

[John H]

TD5 Landy

[apbellamy]

Standard Dash




Diet Dash




Not the most scientific of measuring sticks, but it's good enough as a guide. It had the heater at 7KG ) So with a few other bits and bob's that's 12KG out of it already.