The Gearbox Project

Actually it did not turn out as simply changing a gearbox, but refurbishing the whole enginebay, mounting a new gearbox, changing the clutch and repainting the whole front.

It started in a Cabrio and Classic Rally in September 2003. After 150 km the 2nd and 3rd gear didn't want to contribute anymore to the great result we were aiming at (the year before we ended 2nd!). On 1st and 4th we drove home and parked in the garage.

A refurbished gearbox could be available fast, but the old one should be returned. So dismantling was necessary to do first. I decided to go for it and in the same project to solve an oil leaking of the engine and to clean up the enginebay a little.

Then the big surprise......

I had a 948 gearbox with a 948 clutch mounted an a 1098 engine........

So I had to replace the clutch (the 948 is 150 mm diameter, the 1098 180 mm) and therefore also the flywheel. A used flywheel was found with a very bad starter ring. I had to replace this.
I ended up with changing all the engine gaskets, cleaning and repainting all parts of the engine and respraying the complete engine bay.

Enjoy the pictures!

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November 2003
Having a problem with my gearbox, I decide to remove the gearbox and the motor. See how it looks when I started:

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December 2003

Removing the engine is easy.

This is what I found when I removed all bad spots. I was lucky that it was all 'hard'.

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December 2003 - Replacing the starter ring

I had to replace the starter ring on the flywheel. The one I got had a bad ring on it, so replacing was necessary. Removing the old one was simple, partly cutting with a grinder (careful not to touch the flywheel), and then a final splitt with a shivel.

Shrinking a new starter ring means heating it up to 350 C.
The kitchen furnace just reaches 250 (however my wife did not like the idea of having a rusty Morris part in her furnace). Combined with the flywheel in the freezer I could reach 270 C. Not enough I thought. 

So we prepared a mid-winter barbeque....

Taking care that the ring is not getting overheated (in the meantime a fine carbonizing process is going on).......

If you look good, you can see it in the fire

  

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January 2004 - Respray the engine bay and getting it back together

A respray and laying out the electrical wiring and break pipes.

Starting assembly external brake fluid container, wiper motor, battery, and all the small stuff

A new gearbox and clutch from Ed (http://www.oxfordcars.nl, not sure he is still in business), resprayed all motor parts, exchanged all gaskets.

    

My other friend (Fiat 500, 1970) has to stay outdoor for a while (we moved in 2006, only place for one now.... I sold it)

    

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March 2004 - The engine bay is full again

A great intermediate result.

 

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March 2004 - The front assembled

Putting the front back on again wasn't that easy. It looks like some parts are grown, others didn't.

Well, some parts did really grow: There was paint everywhere.