435 replies to this topic

[jack be nimble]

gearbox is coming apart, bought a gsr box that needs a rebuild, only for the gear case and end cover. it actually doesnt look too bad inside. it has worn synchros on second, and fourth needs better inspection, but the dog teeth look pretty good and even the intermediate shaft bearings look pretty good. if i can get another case and cover it would be worth doing up.
just about to open other box to investigate it.
thanks to brian for the use of his gearbox holder from the other week.
cheers

[EVL JUM]

gearbox is coming apart, bought a gsr box that needs a rebuild, only for the gear case and end cover. it actually doesnt look too bad inside. it has worn synchros on second, and fourth needs better inspection, but the dog teeth look pretty good and even the intermediate shaft bearings look pretty good. if i can get another case and cover it would be worth doing up.
just about to open other box to investigate it.
thanks to brian for the use of his gearbox holder from the other week.
cheers

haha damn if i knew that i would of kept it

[jack be nimble]

hey ben, intermediate bearings need replacing too, if you give me a dead case, i can get you a cheap rebuilt gearbox. i have no issues selling your box back to you rebuilt. lol

my box is short some spacers, chasing:
1.4 to 1.48mm input shaft spacers and,
1.83 to 1.88mm intermediate spacers.

i know inter doesnt come that thick, but we can double them up.

just going to smash this box together with good preloads and use it as i have the other gerbox to rebuild at leisure, i know that inter shaft bearings should be replaced to shorten the shims to preload it correctly, but i will gamble it.
(i will spew if i break it and find out the bearings are 10 bucks each)

[jack be nimble]

had a change of heart and will be buying the bearings for input and inter shafts.

[jack be nimble]

Thank you Your order was placed successfully.
You've just purchased this
1x Output Seal

1x Input Seal

1x CV Seal Output - Pass Side

1x CV Seal Output - Driver Side
1x Input end bearing TOP

1x Input end bearing

1x End Bearing TOP

1x End Bearing
1x Synchro ring

was 180ish posted from jacks transmissions. maybe here next week, i hope

[jack be nimble]

well i got the front converted to 114.3 stud pattern, utilizing tr magna front hubs with the corresponding spline count. no problems, used the magna front discs as well as they are the same diameter as the ute ones. all easy.
only issue is the 18x7 rims with tyres are to big and hit the bottom of strut, so we have steely 15" magna rims on front for now till we can sort it out.
the only differances are that proton have a different sized grease seal on the hub, but we used that seal ok on the magna stubs.
brakes are still improving as the rust wears off the old discs.

pics next week
cheers

[jack be nimble]

in the process of redrilling the rears now. going for 5x100 as rims are multifit. should have dicked about a bit more and gone to 5x114 to match fronts, but too late now. biggest hassle is that i am changing studs to wrx as i have the nuts to suit my rims, but the splined area at the base of the studs are fatter than the jummy ones, and require larger holes. guess what, i have 13mm drill and its too tight for the studs to pull in, and i couldnt get 14mm at bunnings last night, so got 9/16 which is too big. may have to drill at 13mm and file finish them. didnt have issues on the front tho, either different studs front and rear for wrx, or magna studs are fatter than jummy ones.
nearly done though, knock it off in the morning.

got a set of wrx front coilovers left over from old ride for the front of the ute, just gotta change the holes to mount the knuckle and drill the holes at the top of tower to suit three stud. also gotta see how to reduce the steering lock so rims dont hit the chassis rail. its probably in the rack

[jack be nimble]

still waiting for gearbox bearings too. tracking says they in mexico for a week already? glad im not needing these urgent

[brisvr4]

Mexico?? Nothing from the US ever goes through Mexico on it's way here.
I'd be calling Jack to check up on it mate.

[BMGTZ]

I got some pistons and rods out of the US...they spent a few days in CHINA!

[jack be nimble]

progress so far. got rear rims fitted and converted to 5 stud.
fronts are 5 stud too, but rims rub in a few spots so using magna 15" steelies for now

sent message to jack and usps regards bearings, waiting for reply

having issues uploading pics and external linking too. pics to follow...

[jack be nimble]

[jack be nimble]

USPS say that my bearings ended up on the wrong pallet and were sent to mexico by accident. they will redirect and i will get them soon.
hooray

[jack be nimble]

gearbox parts are on the move again, this time in the right direction too.
without the mess up, prob would have made it in 2 weeks

Detailed Results:

Bullet Out of Foreign Customs, April 03, 2011, 3:05 pm, AUSTRALIA
Bullet Into Foreign Customs, April 03, 2011, 2:56 pm, AUSTRALIA
Bullet Arrived Abroad, April 03, 2011, 2:55 pm, AUSTRALIA
Bullet Arrived Abroad, March 15, 2011, 10:14 pm, MEXICO
Bullet Into Foreign Customs, March 15, 2011, 10:00 pm, MEXICO
Bullet Arrived Abroad, March 15, 2011, 9:59 pm, MEXICO
Bullet International Dispatch, March 14, 2011, 5:08 am, ISC SAN FRANCISCO (USPS)
Bullet Arrival
Bullet Processed through Sort Facility, March 10, 2011, 11:22 pm, COLORADO SPRINGS, CO 80910
Bullet Electronic Shipping Info Received, March 09, 2011

[jack be nimble]

bearing arrived, also sold the wrx motor, box and diff that was sitting around, so was a good day alround

[jack be nimble]

busy day in the shed. got all gearbox bits fitted. bit of messing around with pushing bearings on and off, but all good.
shims i ended up needing were 1mm on input (which i had) and .7 for inter, so had a few hours hand filing a shim down to the needed thickness. i superglued it to a bearing shell so i had something to hang on to, and filed it down close, then neatened it up with a coarse then fine stone. no worries there, just time consuming

[jack be nimble]

another busy day, gearbox is complete and ready to go.
engine i finished stripping and plastiguaged the mains and big ends, all within tolerances.
i got a bottom end rebuild gasket set from the us for about $30 shipped, it has sump, oil pump, rear housing, front and rear seals, oil pump oring and a couple of water pipe orings. i see that the manual suggests that you dont use gaskets, but to use sealant. still need the rest of the stuff though. is missing the turbo drain gaskets and the pickup gasket, so will cut these myself.
have reassembled crank and rods, ready to bolt oil pump and crank seals, and sump.
also painted block and oil pan.
all in all a good day.

lest we forget.

[jack be nimble]

got the bottom end finished, so i need to bolt the head on now, but alas i must return to work for a couple of days. tbc..

[jack be nimble]

have had a pretty good run lately. got the front tyres and rims on, got some 215/35/18 and they dont rub at all. rolled rear lips and pulled liners, that fixed rears rubbing.
motor all bolted together, head, manifolds etc. ported exhaust a bit and turbo exhaust manifold to remove ridge and match to gasket.
turbo needs new compressor wheel and rebuild, so ordered parts for it.
pulled loom that has been cut with oxy near the brake booster and fixed that. needed 17 odd wires spliced and new plug and wires for wipers, repin of plug on chassis rail. thanks to my mate adam for his help and constant refills of the beer mug and continuing as i pour over the wiring diagrams to find what wires go where.

also grabbed a hyundai sonata twin cam head for dreaming of a 2.4 twincammer for the ute after the 1.8 is going.
pics to follow

[jack be nimble]

turbo bits have arrived