Came as it has to come. Drove my CS since 2008 and 30k km, but had the first breakdown today.
On my way home from work I shifted down to 2nd gear to pass a slow car and than this happend:
Now 5th gear and reverse arenīt working anymore.
Wouldnīt be such a big problem as Iīve already bought an ST205 gearbox last winter, but Iīm rebuilding my other project car ( a ī86 MR2 ) at the moment and Iīm out of money because of this little money pit.
Checked the Prices for the parts that would be needed to repair the old gearbox yesterday. Much more Money than I will so stick into the old gearbox. So I decided to go for the big solution.
The car will get out of use for the next month or two so i will have the time to buy the parts bit for bit. Bought the most expensive one today:
I will also replace the Timing belt, cam driveshaft and crankshaft sealins, driveschaft boots, the Turbo and the Radiator.
First day is gone. Engine is disconnected, braces are out, frontpipe is removed as well as the probshaft. Driveshafts are bolted off and just have to be took out.
Also testfitted the alu rad but it is so thick that there is no chance so get a fan between the rad and the Aussi downpipe:
Iīve bought two Spal fans, but because of this I only can use one of them:
Here comes my progress of the day. Engine/gearbox out, gearbox removed as well as the clutch and the turbo:
The surface of the flywheel and the clutch plate showing much signs of overheating:
and the clutch discs is nearby worn out even as it only have 70k km done:
As usual I found more things to repair than expected. Will have to get the Aussi downpipe welded as it is cracked:
Removed the turbo as I suspicious it to cause the oil consumtion the car shows since the last year. Will be replaced by a custom made upgrade turbo:
Also startet to overhaul the driveshafts as Iīve seen that they are aged:
What I didnīt expected was to found extremly aged greese. Itīs so hard than I can cut it with a knife:
Good that Iīve bought the ultra expensive original Toyota boot sets for the front and rear driveshafts. Costs 446 � all together, but came with all the bits needed taht aftermarket boots most times miss.
Front:
Rear:
Worked on the engine today and carryed the new gearbox from my shed to my mateīs garage Iīm working on my car.
Replaced the crankshaft sealing and installed the new clutch including the new flywheel the Hyper Singel came with:
Than worked on the other end to replace the power steering pump after cleaning up the mess the old pump leaved behind. The pump is a used ST202 one Iīve bought cheap from a friend. Also replaced the crank and camshaft sealings and the timing belt. Used a timing belt from HKS I bought at the german MR2 board as it was a good deal and sure an upgrade, even as it isnīt necessary:
Finished with new OEM V belts:
BTW, I made a big progress today even as I started working on my car in the late afternoon after help a mate of me to fix his DD.
Replaced the sealings of the new gearbox, switched over the clutch hydraulic and the brackets, bolted it to the engine and pulled the engine back in itīs home:
Still waiting for the sealing for the turbo, but itīs looking good to get her back on the road mid of next week.
The car is getting together bit by bit over the last days, but itīs more work as Iīve expected. Took two days to refurb the driveshafts. Took them apart, wirebrushed the parts with the angle grinder, resprayed them and assembled them back together with new OEM boot kits. Bolted them back into the car, together with the prop shaft.
Replaced the water pump for the intercooler by a used refurbed one as the old one was leaking and noisy:
Also assembled the upgrade turbo:
and bolted it onto the engine with the repair welded Aussi downpipe:
Filled the gearbox with oil ( Castrol 75W140 LSD ) and replaced the oil of the rear diff. Also fitted new spark plugs ( NGK Iridium Grade 7 ) ,a new OEM distributor cap and runner as well as new ignition leads ( Ultra Silicone ) .
Still have to do all the electric connections, bolt the exaust back under the car, put the radiator and the intercooler back to their home and assembel all the rest.
Another day in the garage is gone.
Filled up the engine bay with the missing parts, started to fill up the cooling systems and the power steering:
Switched to the underside of the car to assemble the front axel and bolt the exaust back under the car:
Have to pick up some parts tomorrow but then I have all together to finish this project tomorrow I hope.
Picked up the last parts to finish the project today. Had two adaptors made at a local machine shop to place the sensors for the oil gauges direct in the oil pump. Wanted to get rid of the sandwich plate where the sensors had their home as the old solution was crap and costed ground clearence:
This is the new solution:
With the sensors in place I was able to route the last cabels and finish the project. Only have to put the hood back on:
Season start is coming near. Time to work on the car and spend more money on it:
Made the next purchase some weeks ago. A set of Recaro seats from a JDM ST205 that was splittet for parts. Needed some work, but they was cheap.
Picked them up from the upholsterer today. A part of the center section needed new cloth and the outer cushions had to be repaired with new foam inserts:
The cloth was taken from the rear seats of the donor car, a JDM ST205. The small parts in front of the seats are made to fit the door panels.
Finally received the rails to fit in the seats. Freshly imported from Japan:
Also ordered a rear rollcage, but it will be made and delivered in july. Comes from Safety Devices in UK.
Finally found the time to replace the seats. Still need to replace the cloth of the passenger side doorcard and I will have to mod the seat rails to get the seats more to the rear, but theyīre in:
Modified the Bride seat rails today as I was too big to find a good seating position.
Made adapters to mount the seats more to the rear. Fabricated from 10x40 mm mild steel. All made by myself.
The rails without the extensions:
The rails with the extensions:
The extensions bolted to the seat:
The effect:
Both seats are slided fully backwards. The seat is moved 13,5 cm more to the back with the extensions.
