rx8 gearbox?

[wildo105e]

What size master slave r u using. You could pushing too much fluid and pushing the release bearing too far 👍

[aardvark101]

Thanks for that John !
So gearbox out again today, took a look at the clutch and there are no marks on the springs on the friction plate, so it would appear that there is no contact between the fingers and the springs.

There is marking on the face of the fingers from contact with the release, just missing paint

I put a new release bearing on before i fitted the box, now having looked on line it would seem Mazda changed the design on the bearing in 2009-11, i have the early bearing which has a fixed metal outer ring
and the later ones look like the whole thing rotates, so maybe that the fingers are hitting on the fixed outer ring and are causing the noises.

Also spoke to another chap that has done this conversion and he used a Zetec clutch with no issues, rather than the Pinto that im using, so there is a possibility that the stack height of the Pinto clutch
is too great for the bearing throw.

Wildo, im using a .625 Master Cylinder with the standard Mazda slave.

cheers Paul

[freddy686868]

Thanks for that John !
So gearbox out again today, took a look at the clutch and there are no marks on the springs on the friction plate, so it would appear that there is no contact between the fingers and the springs.

There is marking on the face of the fingers from contact with the release, just missing paint

I put a new release bearing on before i fitted the box, now having looked on line it would seem Mazda changed the design on the bearing in 2009-11, i have the early bearing which has a fixed metal outer ring
and the later ones look like the whole thing rotates, so maybe that the fingers are hitting on the fixed outer ring and are causing the noises.

Also spoke to another chap that has done this conversion and he used a Zetec clutch with no issues, rather than the Pinto that im using, so there is a possibility that the stack height of the Pinto clutch
is too great for the bearing throw.

Wildo, im using a .625 Master Cylinder with the standard Mazda slave.

cheers Paul

That is the problem everyone is using different clutch set up lol. By the sound on it i am using the early bearing with my mk5 rs2000 mk5 flywheel and clutch. Let us know what works for you.

[Eurostang]

Hi all,

I'm currently in the process of fitting one of these to my capri, mated to a rover v8. Has anyone got any photos of how they made up the gearbox mounts?

[Eurostang]

Also to note after reading further back through this post; I let p9cho collect and take my v8 back to his workshop in February to make the prototype. So hopefully soon I'll have some photos to add of how this is looking at some point

[freddy686868]

Also to note after reading further back through this post; I let p9cho collect and take my v8 back to his workshop in February to make the prototype. So hopefully soon I'll have some photos to add of how this is looking at some point

i wouldn't hold your breath he either doesn't produce the plate or when he does it doesn't fit, sorry to tell you. I have had 15 people buy/try to buy a plate off him and have either not got it or threw it in the bin and bough my plates.

[Eurostang]

i wouldn't hold your breath he either doesn't produce the plate or when he does it doesn't fit, sorry to tell you. I have had 15 people buy/try to buy a plate off him and have either not got it or threw it in the bin and bough my plates.

If what you're saying is true I really hope that's not that case especially seen as he has my engine. I've tried calling and emailing again today.

[retrosleeper]

If what you're saying is true I really hope that's not that case especially seen as he has my engine. I've tried calling and emailing again today.

I am one of those people, he took my money and months and months went by along with a lot of false promises even giving dates that were only days away. In the end i was very lucky and got my money back via paypal but had to argue for it as the amount of time that had past was months and months.

on the plus side I have one of freddys plates now and that fits great, fits amazing. I am just doing some work to my wifes mini but then i will be offering up the engine and box to my spitfire and will post some photos showing how good freddys plate is.

[freddy686868]

If what you're saying is true I really hope that's not that case especially seen as he has my engine. I've tried calling and emailing again today.

I don't bad mouth people unless it is the truth and will save others money or hassle. Get your engine back asap and any money you might have given him.

Also read thw whole of this thread through.

[freddy686868]

If what you're saying is true I really hope that's not that case especially seen as he has my engine. I've tried calling and emailing again today.

[Eurostang]

I don't bad mouth people unless it is the truth and will save others money or hassle. Get your engine back asap and any money you might have given him.

Also read thw whole of this thread through.

I finally got in touch! I'm going over tomorrow to collect it.

[bunta20v]

Has anybody got the 2wd Cosworth plate up and running yet? I assume it would work with the standard Cossie flywheel and 240mm clutch.

[Ianbavs]

Not yet been sorting the axle keep us posted if u sort it :-)
I'm gonna try and keep the cable clutch etc


Sent from my iPhone using Tapatalk

[freddy686868]

Has anybody got the 2wd Cosworth plate up and running yet? I assume it would work with the standard Cossie flywheel and 240mm clutch.

I have sold 5 2wd cossie plates so far and everyone was happy. I have also sold a few 4wd ones. I haven't got my next batch of 2wd cossie ones ready yet but i won't be long.

[Eurostang]

I got my engine back!

Does anyone know if the bellhousing is easily removable from the gearbox?

[ugg10]

I got my engine back!

Does anyone know if the bellhousing is easily removable from the gearbox?

What box - on the ford ones usually four bolts inside the bell housing (Type 3 / 9 / T5), if the RX8 if you remove the bell housing part you expose the cogs so it is really and integral bell housing with a split line halfway down the main case.

[freddy686868]

I got my engine back!

Does anyone know if the bellhousing is easily removable from the gearbox?

From what i havw been told the 5 speed has an external/ford type bellhousing. Like ugg said the 6 speed bellhousing holds the main shaft and layshaft bearings for the gears.

[Eurostang]

From what i havw been told the 5 speed has an external/ford type bellhousing. Like ugg said the 6 speed bellhousing holds the main shaft and layshaft bearings for the gears.

Thanks freddy.

The idea is to use the bellhousing from the borg warner 35/65 automatic gearbox (from the rover v8 p6b's) as this fits straight to the block and gets around the need to modify and mess with starters and flywheels and then remove the bellhousing from the rx8 box and mate them via conversion plate at box level. I have a 6 speed rx8 box do you think this is still possible?

[freddy686868]

Thanks freddy.

The idea is to use the bellhousing from the borg warner 35/65 automatic gearbox (from the rover v8 p6b's) as this fits straight to the block and gets around the need to modify and mess with starters and flywheels and then remove the bellhousing from the rx8 box and mate them via conversion plate at box level. I have a 6 speed rx8 box do you think this is still possible?

i doubt it, you will be better off with the 5 speed the way you want to do it but i am still unsure you can do it that way as i haven't looked at a 5 speed in detail.

i am planning on making a v8 rover adaptor plate in the future but i need a gearbox to copy and check the plate on really. It will be just the same as the ford engine conversions easy enough to fit as i hear the rover output shaft is the same as the ford one isn't it?

Here are the photos i have of the 6 speed bellhousing removed

[ugg10]

The alternative to Freddy's adapter is to get a LEEN new front end that you can attach a suitable bell housing for, not sure whetehr they are still in production and cost £1k+ for the aluminium lump but interesting nevertheless.

[Eurostang]

Damn! That kinda ruins my plans for the 6 speed then.

I could try again with a 5 speed or just bite the bullet and source a TVR T5 gearbox

[freddy686868]

Damn! That kinda ruins my plans for the 6 speed then.

I could try again with a 5 speed or just bite the bullet and source a TVR T5 gearbox

Whats wrong with using an adaptor plate? With the rover v8 starter, flywheel and clutch? I was told the rover v8 clutch fits straight onto the rx8 input shaft. Sounds like to me you are making a meal out of nothing.

[freddy686868]

Damn! That kinda ruins my plans for the 6 speed then.

I could try again with a 5 speed or just bite the bullet and source a TVR T5 gearbox

Just found these on another forum. So if i can make an adaptor plate this will soolve your problem

[Eurostang]

Whats wrong with using an adaptor plate? With the rover v8 starter, flywheel and clutch? I was told the rover v8 clutch fits straight onto the rx8 input shaft. Sounds like to me you are making a meal out of nothing.

That's correct the rover v8 clutch fits straight on the rx8 input shaft.

In theory everything should work with an adapter plate. Py9co seems to think this is not possible though? he seems to have had massive issues getting the starter to work which I don't understand as the starter mounts to the engine like so and should not interfere with anything?

[Eurostang]

Some more photos:





I'll try and get some actual shots of my gearbox + engine and flywheel later.

[katana]

That's correct the rover v8 clutch fits straight on the rx8 input shaft.

Py9co seems to think this is not possible though? he seems to have had massive issues getting the starter to work which I don't understand as the starter mounts to the engine like so and should not interfere with anything?

Which sort of reinforces the reason people aren't getting their plates from him! Better to use someone who will actually work through the problems to find a solution?

[freddy686868]

Which sort of reinforces the reason people aren't getting their plates from him! Better to use someone who will actually work through the problems to find a solution?

So true! I have done 2 types of engines with the starters on the engine and it is piss easy. The hardest part about all of the adaptor plates has been getting the starter mounting possition correct. So it is one less problem. The guy is a scrap merchant not an aircraft engineer/cnc machinist of 9 years.

[freddy686868]

That's correct the rover v8 clutch fits straight on the rx8 input shaft.

In theory everything should work with an adapter plate. Py9co seems to think this is not possible though? he seems to have had massive issues getting the starter to work which I don't understand as the starter mounts to the engine like so and should not interfere with anything?

Attachment 78637

These both mount the starters on the blocks.

Vauxhall xe




And the sigma

[aardvark101]

Can anyone with an rx8 box on the bench tell me the internal depth of the hole where the clutch arm pivot bolts in please ?

[Eurostang]

These both mount the starters on the blocks.

Vauxhall xe




And the sigma

This is exactly how I imagined it would work... I've got the engine back now and looking to go down this route. I sourced a manual flywheel, spigot bush, clutch and pressure plate. Weather is shite at the moment but if it clears up I'll get some photos and measurements.

On a slightly separate note: What's the best route regarding a prop? I'd like to get a custom propshaft made up with the shaft end from an RX8 and the other end made to mate to the atlas axle flange. However my propshaft has a centre bearing and most custom shaft + adapted shafts are one straight unit with UJ's at either end. Does this cause any issues? Can the centre bearing be deleted without issue?

[scimitarcars]

I've assembled this conversion for a 2.8 Cologne (carb) conversion. Not actually installed it in the car, only turned it over by hand to check. A couple of things which may help others. There are a couple of different Cologne starter motors, you may have to try a few to find one that fits. The input shaft on the RX box isn't long enough, it'll need an extender. With a 2.8 flywheel, you may need to shim the flywheel away from the crank (these shims are available from the States) to ensure the clutch plate engages fully over the splined 1st motion shaft. I had to pack the clutch arm pivot by about 4mm to give adequate throw.

Also there's a lot of duff information out there regarding the ratios in the 5 and 6 speed boxes. I've found lots of conflicting charts on the web, but the one I'd trust if buying a box in the UK is on the original sales brochure. See page 31 on the PDF file linked here.

http://www.mazda.co.uk/assets/uk/use...8_brochure.pdf

[freddy686868]

I've assembled this conversion for a 2.8 Cologne (carb) conversion. Not actually installed it in the car, only turned it over by hand to check. A couple of things which may help others. There are a couple of different Cologne starter motors, you may have to try a few to find one that fits. The input shaft on the RX box isn't long enough, it'll need an extender. With a 2.8 flywheel, you may need to shim the flywheel away from the crank (these shims are available from the States) to ensure the clutch plate engages fully over the splined 1st motion shaft. I had to pack the clutch arm pivot by about 4mm to give adequate throw.

Also there's a lot of duff information out there regarding the ratios in the 5 and 6 speed boxes. I've found lots of conflicting charts on the web, but the one I'd trust if buying a box in the UK is on the original sales brochure. See page 31 on the PDF file linked here.

http://www.mazda.co.uk/assets/uk/use...8_brochure.pdf

Another way to sort the spline issue is to machine the face of the rx8 bellhousing to move the input shaft into the motor but in the end it is the same result.

[freddy686868]

This is exactly how I imagined it would work... I've got the engine back now and looking to go down this route. I sourced a manual flywheel, spigot bush, clutch and pressure plate. Weather is shite at the moment but if it clears up I'll get some photos and measurements.

On a slightly separate note: What's the best route regarding a prop? I'd like to get a custom propshaft made up with the shaft end from an RX8 and the other end made to mate to the atlas axle flange. However my propshaft has a centre bearing and most custom shaft + adapted shafts are one straight unit with UJ's at either end. Does this cause any issues? Can the centre bearing be deleted without issue?

Almost everyone used to have a 2 peice prop in thier escorts and convert them to a single piece. You could send your prop off to be refurbed/shortened and the rx8 end put on that if you would like to keep the center bearing. Look up bars props neath to ask them what prices you would be looking at and what they would recomend is the best idea.

[scimitarcars]

Another way to sort the spline issue is to machine the face of the rx8 bellhousing to move the input shaft into the motor but in the end it is the same result.

That would go some way to helping the issue. But I don't think you could remove enough material to still not have to use an extender. I think the thing to remember is that when you fit a V6 T9 to a four pot, you have to cut the input shaft down. If you do the reverse, you have to make up a short extender or replace the shaft for a V6 version. IIRC there's about 30mm difference in the length of shafts between V6 and 4cyl T9. I know we're not using a T9 in this instance, but the same situation applies that if you're using the RX8 box on a V6 Cologne, you'll need a longer input shaft that you would do for a 4cyl Pinto etc.

As you've said, you could machine the bell housing. But I doubt you could remove approx 30mm.

[freddy686868]

That would go some way to helping the issue. But I don't think you could remove enough material to still not have to use an extender. I think the thing to remember is that when you fit a V6 T9 to a four pot, you have to cut the input shaft down. If you do the reverse, you have to make up a short extender or replace the shaft for a V6 version. IIRC there's about 30mm difference in the length of shafts between V6 and 4cyl T9. I know we're not using a T9 in this instance, but the same situation applies that if you're using the RX8 box on a V6 Cologne, you'll need a longer input shaft that you would do for a 4cyl Pinto etc.

As you've said, you could machine the bell housing. But I doubt you could remove approx 30mm.

machining the bellhousing was my solution to the clutch/spline contact area problem you would have to use an extender too unless you machine the flywheel to take a bearing like a customer of mine has done. There are many ways to do it though. Also for reference you can take up to 14mm off the bellhousing of the rx8 box before you start machining off the slave cylinder mounts.

[scimitarcars]

Another potential help would be the use of a 2.9i flywheel, which is thicker than the 2.8 version. You can buy them new from the USA, but you'd need to use a Ford Bronco clutch pressure plate or re-drill for the Euro Ford clutch.

By the way, I have to say that your plates look to be nicely done freddy. If I was looking for another, I'd be buying one yours next time.

[freddy686868]

Another potential help would be the use of a 2.9i flywheel, which is thicker than the 2.8 version. You can buy them new from the USA, but you'd need to use a Ford Bronco clutch pressure plate or re-drill for the Euro Ford clutch.

By the way, I have to say that your plates look to be nicely done freddy. If I was looking for another, I'd be buying one yours next time.

interesting about the 2.9i manual flywheels what is a rough price on them? as it could be the answer to a few problems.

Thanks for that i take it your using a psycho plates one then?

[scimitarcars]

The US flywheels are upwards of £50. And yes I have p9yco plate. I have to say though, it was a comprehensive kit and did exactly what it was supposed to do. My only observation would be that it was a bit roughly cut.

[scimitarcars]

Another potential help would be the use of a 2.9i flywheel, which is thicker than the 2.8 version. You can buy them new from the USA, but you'd need to use a Ford Bronco clutch pressure plate or re-drill for the Euro Ford clutch.

By the way, I have to say that your plates look to be nicely done freddy. If I was looking for another, I'd be buying one yours next time.

I did have all the spec's and measurements for the US Cologne flywheels but can't find them at the moment. But I "think" this is the one http://www.ebay.com/itm/221170168023 . As I mentioned earlier the locating holes for the clutch plate are wrong for Euro clutch kits. But nothing is insurmountable with a bit of tinkering.

[Eurostang]

I don't like giving up but After some consideration I'm going to bow out of the rx8 conversion and go down the more conventional T5 box route.

I did take some photos if they're of much help to anyone looking to tackle this in the future!

Google Photos Album

My 6 speed rx8 box is up for sale if anyone here is looking give me a PM.

Thank you everyone for the help!