C160SFG - 1986 Series 3

[spoddy]

Really good work Ian, must be enjoyable to work on too.

[ian65]

Really good work Ian, must be enjoyable to work on too.

thanks Ronnie, it's progessing (slowly)

[myatt1972]

Great work Ian, can't fault your research into all these niggly bits

[Tepper]

Watching with interest, looking great so far. If you need anything small/light from the States I've got a trip coming up next month, I'd be happy to bring back a few bits if needed. Drop me a PM!

[ian65]

Watching with interest, looking great so far. If you need anything small/light from the States I've got a trip coming up next month, I'd be happy to bring back a few bits if needed. Drop me a PM!

thanks Will, if I think of something I need I'll give you a shout

[ian65]

A bit more work on the TII turbo swap today...... altering the turbo II transmission so that it fits in the FB without altering the bodywork.
The problem is that the Turbo II gearbox is slightly longer than the stock FB box and throws the gear lever up out of position. There are 2 options..... bodge it and cut the bodywork around the gear surround or modify the gearbox by shortening the selector rod and tube and fit a series 3 gear lever housing which is what I'm doing.

First job was to take the tail section off the transmission...










and removed the TII gear lever housing...






For comparison the TII housing and the series 3 housing showing how much the gear lever position will be moved by..... a strange thing is that both selector tubes are the same length ...






Still to modify is the selector rod...





This needs a new hole drilling 30mm further back the the existing hole and the 30mm cutting off the end of the rod....






The selector tube has been cut down and the end seal replaced...






and the tail shaft de-greased ready to go back on...





Once the selector rod is modified, the tail shaft can go back on and it should be job done.


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[spirit r]

Wow, that was a realy good S3 specific explanation. A bad speaking english will understand them without Google translate.

[ian65]

today pressed on with modifying the shifter position....
the selector rod needs a new hole drilling in it for the bolt 30mm along from the existing bolt hole...



this isn't as easy as just drilling a hole though... the new hole needs to be in exactly the same plane as the existing hole, not leaning to either side of the rod. Thanks to Keith and his workshop of wonderment we managed to get it spot on by using a pillar drill to set the position of the rod by lowering the drill bit through the existing hole, tightening the rod into the hand vice then sliding it along and drilling the rod in the new position...we then ran a slightly larger drill bit part of the way through to house the shoulder of the bolt...




The selector rod tube carries gear oil and has a bonded on rubber sleeve at each end to seal it to the gear lever housing and the gearbox tail housing. To shorten the tube I had to carefully cut around the seal at one end of the tube, prise it off, cut the tube then superglue the seal back on. I then put a touch of RTV on each end to seal them into their seats when the tube was installed...





Series 3 shifter housing fixed to the TII tail housing...








the following photo shows the how shortening the selector rod, tube and fitting the series 3 shifter housing has moved the shifter / gear lever position forward so that it lines up with the hole in the transmission tunnel and the centre console. The housing on the left is the modified one whilst the one on the right is the stock Turbo II item...





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[ian65]

Clutch installed...







.

[Hobbawobba]

Good to see the shortening Ian. I've seen it mentioned a few times but never actually seen pictures of it done! Nice progress as usual