Gearbox swap Help needed please :-))

[marcher]

Hi chaps,

Here i am needing help again

I have bought a 091 6 rib box and starter in hoping to fit it to my bus. I have done nothing about it yet, but i'm hoping to get a few pointers before i take out my 1600 gear box.

i'm running a standard 1600 set up.

I have read up and it seems quite easy :shock: :shock:

so, do i need to a 2.0l clutch???
Will it be as easy as it sounds????
Do i need to change any thing on the nose of the 091????
Should the mounts all be the same???
Will the engine run hotter if the gearbox is do less Revs (fan turning slower)?????

I have read Garys(slamresto) thread and all he needed to do was to grind of 2" from the shaft, are they all the same???

Would like to fit this myself, but just after some advice before i get to involved.

cheers

 

[ianscooby]

marcher

collected mine last week from slammedkustom (cheers ) so will be doing the same, so any help assistance as you say would be appreciated

BTTT

 

[marcher]

cool m8.....we can both make an arse of it together :lol: :lol: :lol: :lol:

 

[richbaker78]

been a few years since i did this....it will be as easy as it sounds

you will need to swop the early bay nose mount with the late bay U type nose mounting - this is just two blots - str8 swop.

Use the 1600 clutch and friction plate.

later 2L boxes have mounting lugs over the gearbox bellhousing (as per late bays) but you just dont use these - i actually swopped bellhousing too as this meant i could use the standard 1600 starter too.

the input shaft on the 2l is 10mm longer. the best way to get round this is to replace it with the 1600 input shaft - this is an easy if fiddly job (se your haynes manual for details) however some people opt to just cut 10mm off the nose.

Finally i was told that I would need to shorten my gear shift rod by redrilling the grub screw locating hole (nearest the front) 10mm further back. In the end this wasnt neccesary for me but my mate that did the same conversion had to on his for some reason....so leave this till last and see if it puts your gear shifter out of place!

hope that helps a bit!

 

[marcher]

richbaker78,

Cheers for the info m8, really helpfully. I starting to think that i "should" be able to tackle it :roll: :?

do you know any thing about the engine running hotter?????



Does anyone think it is "overkill" to fit a 2.0l box to a standard 1.6 engine???? will i notice any difference to speed/MPG etc etc

 

[maddog]

Drove mine today for the first time with a 091 box.

OK its a race built box but no you shouldn't expect any hotter driving conditions or if so just a little........i say this as mine runs a little hotter but then again the engine's a little 'hotter' too

1st/2nd & 3rd gears are longer and you should notice a drop of about 800rpm in 4th. Of course this also depends on wheel/tyre size.


Cheers
MD 8)

 

[richbaker78]

no probs marcher.

i would say that the differences you will notice with a standard 2l box will be minor but there will be a slight (not as much as mad dogs modded box) gain in cruising speed and MPG and a slightly earlier change down for going up hills!!! i wouldnt wory about cooling issues but in the unlikely event you do have probelms just add an exteranl oil cooler.

I dont think its overkill - especially if you intend to upgrade the engine in the future. 2L boxes are getting rare and expensive so worth having it in in case one day you get a decent powered engine. Then you can step up to a really long legged built version of the box like the one Maddog (and I) have.

one thing i forgot to mention - drain the gearbox oil before you remove the bell housing. also its worth replacing the inpuit shaft oil seal whilst your there (only a couple quid at gsf). Use blue hylomar to re-seal the case to the bell housing.

Maddog is correct also - one of the biggest changes you can make to cruising ability is wheel/tyre diameter - keep as close to original size as you can to max it out. Its cheap and easy to do!!

 

[maddog]

Rich, i'm intrigued - what you running?

 

[richbaker78]

cant remember the spec/ratios (as said above was a long time ago!) but the box was modded by cogbox with tallest 4th gear they could squeeze in. drops about the same rpm off as you quoted for yours so had assumed it was similar. Mines coupled to a 245bhp 2l WRX engine though with RJEs bellhousing and running the t25 hydraulic clutch! (not up and running yet tho)

 

[marcher]

:shock: :shock: :shock: :shock: :shock: 245 bhp in a bus :shock: :shock: :shock:

 

[maddog]

8) Beats me, i've only 220HP but with a Type 1 motor.

Yes, mine's also a Cogbox built box and sounds very similar to yours Rich.

Question is, are you gonna come and have a play out on the strip soon?

MD

 

[richbaker78]

dont know about soon..... i still have a lot of work to do on it. but when its done i will prob do a few runs
245 is pretty much standard - once the vans all done my intention is to start tuning it.
220 is impressive from a T1 enigne tho! bet that wasnt cheap!!!

 

[maddog]

Nice one!! Good luck with the project and let us know when its all up and running

Yes its goes alright
Get what you pay for......JMR built, so you can guess

MD.

 

[ianscooby]

been away for a couple of days, a belated thanks marcher for putting this up and thanks all for providing the info.

just one other :?: , I have clutch slip since fitting a 1776, do I need to change uo to a stage one clutch

 

[richbaker78]

i would have thought so although it depends on the output of your engine / how you drive it etc. i used to run a kennedy stage 1 with my 1776 which worked fine. i would remove your existing though and see if there are any other reasons such as normal wear etc first though.

 

[maddog]

^^^WHS^^^