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 Engine out/investigate gearbox 
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Stylus owner

Joined: Fri Mar 10, 2006 8:49 pm
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Post Engine out/investigate gearbox
I put the car up on axle stands this morning ready to start getting the gearbox out , to investigate what's happened at my Goodwood test day (jamming in 4th and 5th)
Took the flip front off , drained the water and disconnected all the hoses , fuel lines , breathers plus all electrics . It's ready to unbolt everything now , starting with the throttle pedal end cable which is easy enough to get out but not so easy to put back in , so that you get full throttle when your foot's on the floor :wink:
Hopefully I'll get the engine out tomorrow , if the exhaust manifold bolts play ball (put them in with threadlock :roll: ) It takes ages cleaning out the bolt holes with brake cleaner and a bent wire :x
Old bones don't help either :lol:

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I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Mon Apr 22, 2013 2:39 pm
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Joined: Sat Apr 07, 2007 10:24 pm
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Location: Chester UK
Post Re: Engine out/investigate gearbox
hmmmm, you may live to regret the threadlock! :shock:
good luck.

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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams. (aka NORMA)
Lotus Exige S1 with 340bhp Audi engine conversion
VX220 NA - orange of all colours
Audi S3 8L
VW Touareg R-Line
17 seater LDV 400 minibus (for track work obviously)


Mon Apr 22, 2013 10:53 pm
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Location: Chesterfield
Post Re: Engine out/investigate gearbox
Would it not be easier to clean the threads with a tap? Flushing with cleaner between rums throughs?


Mon Apr 22, 2013 10:58 pm
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Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
CMA wrote:
Would it not be easier to clean the threads with a tap? Flushing with cleaner between rums throughs?


It occured to me the last time it had to come out , due to the bellhousing parting company with the box BUT was fearful of the ally head threads being damaged . It's the soft locktite not the very stiff one --- I forget the actual number now but it's the one you use if removal is necessary on regular basis :roll:
The brake cleaner does a fair job but it's a fiddle. First job tomorrow :)

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Mon Apr 22, 2013 11:13 pm
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Joined: Fri Apr 16, 2010 9:32 pm
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Location: Chesterfield
Post Re: Engine out/investigate gearbox
I've just refreshed all the threads on my zetec head using a tap and had no issues, they didn't have thread lock in bit some were seriously gunked up with stuff.


Mon Apr 22, 2013 11:36 pm
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Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
Took your hint on using a tap Rob , yes it worked very nicely along with the brake cleaner but I didn't use the final tap from the set --- just the middle one as there's a little more gradual start on it :)
Once the exhaust manifold was off , I cleaned up the bolts and threads , ready for going back on then took the starter off . Inner wheelarch engine guards are now off so it's engine mounts , ARB and tower brace then bellhousing bolts , ready for the lift out tomorrow hopefully at some point.
Lots to do other than the Stylus on Thursday/Friday then I'm off to Goodwood to assist Simon with his Jedi on Saturday's Bognor Regis Sprint (where I should have been in my car :x ), so no more on the spannering till next week.
I'm quite enjoying driving the Alfa 159ti road car at the moment so a run down there and back will be quite nice at 6-30am , especially now it's got Eiback springs and Bilstein B6 shocks :P
Simon did very well for his first ever drive of a single seater at N Weald last Sunday , getting 1st in class (no others in his class :wink: ) plus FTD at a cool 5 seconds quicker than anything else there on the day --- nice :D

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Tue Apr 23, 2013 5:42 pm
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Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
Engine out , box out and lid off inspection ---- looks clean and no burrs on cogs or rings , also the oil was totally clear of any bronze filings etc when drained last week . All gears easily selectable and roll pin was in flush on the selector block ---- so no simple answers .
Looks like a chat with Brian Hill and a trip to KENT .

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Wed Apr 24, 2013 4:04 pm
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Joined: Fri Apr 16, 2010 9:32 pm
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Post Re: Engine out/investigate gearbox
stylussprinter wrote:
Took your hint on using a tap Rob , yes it worked very nicely along with the brake cleaner but I didn't use the final tap from the set --- just the middle one as there's a little more gradual start on it :)
Once the exhaust manifold was off , I cleaned up the bolts and threads , ready for going back on then took the starter off . Inner wheelarch engine guards are now off so it's engine mounts , ARB and tower brace then bellhousing bolts , ready for the lift out tomorrow hopefully at some point.


Good to hear it worked. I always start with the 2nd tap and only use the bottom (final) if I need to clean right the the bottom of a blind hole. Sometimes of its really clogged up I use the starter tap then move onto the 2nd.


Wed Apr 24, 2013 8:32 pm
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Joined: Sat Apr 07, 2007 10:24 pm
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Post Re: Engine out/investigate gearbox
If I'm just chasing a thread and I haven't got a tap then I just use a cutting disc on a grinder and cut 2 or 3 slits up a bolt to accomodate any swarf and then use that - normally does the trick.

_________________
SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams. (aka NORMA)
Lotus Exige S1 with 340bhp Audi engine conversion
VX220 NA - orange of all colours
Audi S3 8L
VW Touareg R-Line
17 seater LDV 400 minibus (for track work obviously)


Wed Apr 24, 2013 9:27 pm
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Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
Just back from Brian Hill BGH GEARTECH down in Cranbrook . Quite a lot to do in the box once it was stripped . Baulk rings with tabs snapped out plus 3 were cracked very fine so couldn't see looking in the top. Seeing as labour is the same for stripping/rebuilding , it made sense to renew anything not 100% , so new front and rear heavy duty needle roller bearings plus other bits/bobs ----- totalling £454-19p with vat.
BRILLIANT service though --- he was very busy with stacks of work already waiting but after a chat , I cleared off to the village for something to eat around 12-00am while Chris and Brian repaired my Quaife clubmans T9 ---- I collected it done and dusted at 5-00pm

That saved me driving another 100 odd miles there and back again to get it next week :P
Can't praise BGH enough , they really know boxes and have made many improvements .

So just got to get it all back together now plus a few little jobs I've seen need doing since taking the engine out :roll:

Top outer rodends , no play in them but kevlar hanging out of the spherical ball so not taking chances ----- plus a little rust on the surface of the underside lower chassis tubes

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Mon Apr 29, 2013 10:23 pm
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Post Re: Engine out/investigate gearbox
that is VERY good service, price seems ok too to be honest.

_________________
SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams. (aka NORMA)
Lotus Exige S1 with 340bhp Audi engine conversion
VX220 NA - orange of all colours
Audi S3 8L
VW Touareg R-Line
17 seater LDV 400 minibus (for track work obviously)


Mon Apr 29, 2013 10:42 pm
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Joined: Fri Mar 10, 2006 8:49 pm
Posts: 3709
Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
Might even get an event in before the TWMC Sprint in June :roll:

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Mon Apr 29, 2013 10:45 pm
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Joined: Sun Mar 15, 2009 2:24 am
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Location: northants
Post Re: Engine out/investigate gearbox
Good news :D try and find a garage to do that kind of service!

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Tue Apr 30, 2013 12:22 am
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Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
bluestu wrote:
Good news :D try and find a garage to do that kind of service!


He's brilliant , I really like Brian and his humour , typical ex-services engineer and unbelievably still working at 82yrs old . Chris working with him and doing most orders now , is also VERY knowledgable . Their ideas on how to sort power/box problems on the hoof is excellent . Things we talked about yesterday plus little pieces of own design rings , cones etc --- just amazing that no big name people come up with this stuff 8)
I didn't know much about boxes before , hence not ever taking one apart but know more about each bit's function after yesterday :)
If I had left the box with them for a month or more , the solution requiring the cones turned then fitting their new ring design could have been done ----- too long to wait so hope it lasts as long as his last rebuild in 2007 :D
Another little bit of info re -- Brian . He was the guy who designed Caterham's original 6 speed development box :P

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Tue Apr 30, 2013 9:37 am
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Posts: 3709
Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
I bodged up a gearbox oil catch/return over the pinhole in the lid yesterday. Only a very small amount seeps out and lays around the edge , not enough to run down or drip underneath but thought I'd try to keep it dry.
You'll laugh when you see the photo but it'll do the job --- I think :P It can't be seen when the box is in the car so that will contain my embarasment :oops: I've used one end of a plastic 100ml syringe , glued upside down over the pinhole in the lid so it can still breath via the needle end then run back into the box .Got to check that it's stuck nice and solid yet ---- pic to follow :)

_________________
I just love the Stylus but she keeps swallowing £££ !
[b]Alfa Red 159 2.4 jtdm ti 260bhp 365lbft / BilsteinB12 + Adjustable Powerflex camber/castor bushes. Red STYLUS 2lt zetec 231bhp 185lbft Dunnell . RED 1972 Alfa 2lt GTAm replica 170bhp.


Wed May 01, 2013 8:44 am
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