Posts Tagged ‘Gearbox’

Engine Fitted

Posted: 26th November 2011 by asteriskr in Rallye 16v
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Engine is back in (temporarily)

Engine and Gearbox


Posted: 14th August 2011 by asteriskr in Welding
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Update time! Well with holidays and a bit off a lengthy spell battling the N/S inner wing, there’s finally some progress to report. First of all though I managed to pick up a S2 Rallye Gearbox Pinion and Crownwheel that is already prepped and ready for fitting to a Quaife ATB limited slip differential. This has the 16 tooth pinion and 65 tooth crown wheel giving a 4.06 final drive.

S2 Rallye Crown Wheel and Pinion

S2 Rallye Crown Wheel and Pinion

N/S inner wing works are finally complete. In the end I cut out a section I was unhappy with and redid it and it took a lot of time to get it all to a standard I was happy with. The inner wing is currently being prepped for primer. As this was now essentially finished off, it was time to do another job that I’d be waiting to get done – filling in the holes in the firewall bulkhead that are going to be surplus to requirements. One hole is from the fuel lines the other was used by part of the wiring loom. Some of the metal sections chopped out were a little rusted anyway either way it would have needed some attention.

Bulkhead patching

Bulkhead: removed sections

Bulkhead: patched

Baker BM Mounts

Posted: 13th June 2011 by asteriskr in Rallye 16v
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Baker BM have been doing an uprated gearbox mount for some time and a mounting for the engine for the first series Rallye, but the engine mount for the series two is new. I was down on the waiting list and mine came though in the post earlier today. They’re called group N mounts, but basically are firmer rubber with more substantial inserts. The engine mount also uses a larger diameter effective bolt as the standard one is prone to snapping.

Engine Mount
Baker BM Group N Engine Mount

Baker BM Group N Engine Mount

Gearbox Mount
Baker BM Group N Gearbox Mount

Baker BM Group N Gearbox Mount

My standard gearbox mount was pretty goosed.
Standard Gearbox Mount

Standard Gearbox Mount

A Little Progress

Posted: 8th November 2010 by asteriskr in Rallye 16v
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This is the standard speed sensor and mounting bolt on the gearbox.

Gearbox Speed Sensor

I didn’t like the rusty bolt so I’ve upgraded it to a titanium one

Gearbox Speed Sensor Mounting Bolts

It’s a M7 bolt with a 1.00 thread pitch with a length of 16mm. It’s also a cap head rather than a normal bolt head like some of the earlier cars. It’s a rare size so finding one tooks some tracking down, but in the end I sourced one though Singapore.

Gearbox Speed Sensor

Fitted… some other trick bits are in the post to fix up my latest purchase to my exacting standards

Gearbox Done

Posted: 19th October 2010 by asteriskr in Rallye 16v
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Gearbox finished tonight and reassembled with all new seals on the driveshafts and input shaft as well as the 5th gear gasket. At the weekend I may flat down some of the black coated sections and apply a new top coat. There are also a couple of spots I missed with the enamel, but in all it is 100 times better than what I started with!

Before & During:

Dirty Gearbox Gearbox being Cleaned

Gearbox Refurbished