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clubstylus - View topic - Engine out/investigate gearbox
It is currently Sun Jan 19, 2020 11:46 pm




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 Engine out/investigate gearbox 
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Joined: Fri Mar 10, 2006 8:49 pm
Posts: 3750
Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
All very solid this morning , although does look very odd , especially the pink resin glue :oops: I scratched all the gold paint off and scored the metal before putting it on.

Might want to paint over the glue :lol:
If of course , I'd done it before taking the box down to Brian , then it could have been a metal tube but didn't think about it at the time :roll:


Attachments:
gearbox '' syringe '' breather 003.jpg
gearbox '' syringe '' breather 003.jpg [ 1.1 MiB | Viewed 5656 times ]
gearbox '' syringe '' breather 002.jpg
gearbox '' syringe '' breather 002.jpg [ 1.19 MiB | Viewed 5656 times ]
gearbox '' syringe '' breather 001.jpg
gearbox '' syringe '' breather 001.jpg [ 1.03 MiB | Viewed 5656 times ]

_________________
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 9:22 am
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Joined: Fri Mar 10, 2006 8:49 pm
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Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
Better now :)


Attachments:
File comment: paint plus cycle tube !
gearbox '' syringe '' breather.jpg
gearbox '' syringe '' breather.jpg [ 1.13 MiB | Viewed 5651 times ]

_________________
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 10:51 am
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Posts: 3750
Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
Just ordered a new clutch bearing seeing as it's a lot of work to remove and refit the engine and box . Can't actually see much wrong with it but better safe than sorry :roll: I'll give the system a fluid change too while at it.
Also bought some blue gasket seal because although when I last fitted the box/bellhousing together it had new paper gaskets ---- that top rod that extends through the box still allowed a small leak . The area between the rod and bellhousing is really small , to get a nice seal.

_________________
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.


Thu May 02, 2013 11:05 am
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Joined: Fri Mar 10, 2006 8:49 pm
Posts: 3750
Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
Box is back in place bolted down , speedo connected and the breather has 40mm's clearance from under the tunnel . Waiting for bellhousing gasket , otherwise am ready to refit that plus the ally clutch slave cylinder nose and bearing , pipes etc . The bellhousing will go in with blue locktite and norlock double washers , plus 15% higher torque than normal ------ re - the loosening problem last year :o
I've got one gasket but forgot that I use a 2mm spacer between my box and bellhousing for correct bearing to cover fingers gapping , so need two :oops: . This box is from a Caterham so has a longer shaft.

Did a little rust/grime cleaning of chassis members and hamerited those plus the engine mounts before the engine goes back in.

_________________
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 May 07, 2013 3:32 pm
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Joined: Sat Dec 24, 2011 12:20 pm
Posts: 98
Post Re: Engine out/investigate gearbox
Rob,

Just a thought- is it worth making a quick jig for the engine mounts whilst they are out? I'm sure you could sell some to people converting to zetec. I had a right mare sorting mine as I couldn't fab anything myself at the time


Tue May 07, 2013 6:25 pm
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Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox

_________________
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 May 07, 2013 7:01 pm
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Joined: Sun Aug 19, 2007 3:30 am
Posts: 33
Location: Regional South Australia, Australia
Post Re: Engine out/investigate gearbox
Hi Rob, rossco61 in Sunny South Australia.
Just tried to send a PM to you, re upcoming trip to the UK, but the system will not allow it ??
Can you please contact me via "rossco73@bigpond.com"


Thu May 09, 2013 3:29 am
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Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox

_________________
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.


Thu May 09, 2013 8:34 am
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Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
Off out to lunch today so engine won't be going in but did get the gasket I was waiting for yesterday , so the bellhousing/gasket/spacer/gasket are all bolted up/hylomar tight , with techy washers/locktite(85ft.lbs) . Hydraulic clutch nose/spacer also back in with locktite but being into ally was really careful putting just 4ft.lbs extra . If it could be got at once fitted from outside then I'd have stuck to my usual 12ft.lbs BUT last year's fiasco with the b.housing coming adrift from the type 9 has made me extra cautious ----- engine out just to see what's happened doesn't appeal :x

_________________
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.


Fri May 10, 2013 9:21 am
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Joined: Wed Jan 24, 2007 10:31 pm
Posts: 81
Location: BRIGHTON
Post Re: Engine out/investigate gearbox
Rob and rossco, if the weather is good I might drive the stylus up to Manchester from the south coast on Saturday the 8th. I could detour via Aston Clinton. Will you still be around?
Rossco, I' m also an Aussie, been living here 22yrs but heading back to sydney in December. I haven't yet looked into what's required but do you know of any particular issues getting a kitcar road registered? And do the different states still have different laws for registration?
Mike


Sat May 11, 2013 10:10 am
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Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox

_________________
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.


Sat May 11, 2013 11:01 am
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Joined: Fri Mar 10, 2006 8:49 pm
Posts: 3750
Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
Engine's back in place today , just some electrics to connect and re-fit the exhaust manifold , silencer etc -- fill up with water/water wetter , oil in box then re-fit the flipfront and tidy up the tunnel after removing everything to check the box . Feel better now it's got this far , the rest is easy and there's plenty of time before my first outing in June at Goodwood .
It's been a more expensive excersize than last year's fiasco with the bellhousing parting company with the box , in spite of master cylinder and slave cylinder rebuild kits plus new ring gear , it still only cost me £250 to sort , although still bloody hard work .
This box along with other items needed , with engine out etc totted up to over £600 :(

I competed for years without any reliability problems and now that I only do 3 to 5 events a year , it seems to be costing loads . I suppose the 8000 rpm plus doesn't help the box any , although it has been extensively modified OR maybe I'm using that 8000rpm more of the time than when I first had it available :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.


Sat May 11, 2013 7:36 pm
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Joined: Fri Mar 10, 2006 8:49 pm
Posts: 3750
Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
Finished all electrics and re-fitted the exhaust manifold plus silencer ---- no more today , seeing as I wanted to watch Spanish F1 .

_________________
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.


Sun May 12, 2013 8:17 pm
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Posts: 3750
Location: ASTON CLINTON BUCKS
Post Re: Engine out/investigate gearbox
Millers 75w90 Nanotech oil in box (1.6lts including 100mls ZX1) Quite a bit of disagreement over Type 9 oil levels . I've previously put 1.9lts in but asked BGH and they say that early boxes had 1.9 but later boxes (with identical gearsets and case volume) had 1.6 advised by Ford.
The confusion seems to be over the height of the filler plug up the side BUT boxes are identical and ' apparently ' Ford later found that 1.6lts was adequate , after complaints of leaks/pressure --- so made later boxes with the lower filler height to make filling the right amount simple.
Hope it's correct after spending out big bucks on this latest repair --- at least it's got ZX1 plus the all singing , dancing gear oil --- plus my little breather so the oil stays inside the box. Pulling 8,000rpm is probably well beyond the original design spec :shock:

Millers 5w40 Nanodrive in the engine plus ZX1. Water back in the system but yet to have water wetter added to be run and bled.
May get the coilovers and strut brace in tomorrow plus fit the new rodends . Then the clutch needs new oil and bled --- getting there :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 May 13, 2013 4:27 pm
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Joined: Sat Apr 07, 2007 10:24 pm
Posts: 333
Location: Chester UK
Post Re: Engine out/investigate gearbox
sounds like you're cracking on.
Mine's looking at spending year 3 on ramps :-(
There's a broken VX220 to fix first as well!
Oh and a 3 week old daughter..... may as well give up now :lol:

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SSC Sylus 2.0 Dunnell Black Top Zetec weber alpha / DTA + cams, 236@fly. (aka NORMA)


Mon May 13, 2013 9:16 pm
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