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Thread: Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

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    Spanner Monkey ugg10's Avatar

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    Re: Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    No, on the Anglia it is way too long. I will give neath props a call as they are recommended by Freddie, I think they can make one up with the rx8 front and my small flange english diff rear end. Will get the rear mount sorted then order that.
    1968 Ford Anglia 1.7 Puma engine/Escort front/5 Link rear/RX8 box
    http://www.Anglia1968.weebly.com

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    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    Quote Originally Posted by ugg10 View Post
    No, on the Anglia it is way too long. I will give neath props a call as they are recommended by Freddie, I think they can make one up with the rx8 front and my small flange english diff rear end. Will get the rear mount sorted then order that.

    Brilliant progress on the build! I like the use of a clutch cable too. Looks like a simple but effective solution.

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    Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    Carbon prop shortened to 48.5" cost £165 weight @ 7.7kg with Cosworth/atlas flange
    Going to fit this n rx8 6speed when the t5 gives up as lay shaft bearings are noisey 😱
    Any decent quick shifts for the rx8 6 speed box for sale anyone ?


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    Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    Make that 6 kg instead 🙄


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    Re: Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    Quote Originally Posted by Ianbavs View Post
    Carbon prop shortened to 48.5" cost £165 weight @ 7.7kg with Cosworth/atlas flange
    Going to fit this n rx8 6speed when the t5 gives up as lay shaft bearings are noisey ��
    Any decent quick shifts for the rx8 6 speed box for sale anyone ?


    Sent from my iPhone using Tapatalk
    Thanks for that, bit of bad timing though, just shelled out more than that for a heavy duty steel one, did come within four days of order though. A carbon prop would have been a nice bit of bling on the car !

    I thought the RX8 had had a quick shift anyway, certainly quicker than the type 9 ?
    1968 Ford Anglia 1.7 Puma engine/Escort front/5 Link rear/RX8 box
    http://www.Anglia1968.weebly.com

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    Re: Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    Axial Flow do them but at a price (£250 ish), may be worth looking at other cars that use this gearbox - BRZ/GT86, IS200, MX5 mk3, S15 200SX.
    1968 Ford Anglia 1.7 Puma engine/Escort front/5 Link rear/RX8 box
    http://www.Anglia1968.weebly.com

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    Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    Yeah cheers for that will keep look out :-)


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    Re: Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    Quick update on my Anglia RX8 install.

    All now in and connected with propshaft !!!

    A few pics of my mount which fortunately lined up well with the Anglia cross member. This is basically a re-creation of the type 9 mounting on the rear of the RX8 box -

    Top plate made to match the gearbox, note extra bit on the front to mount speed sensor but this hits the prop UJ, now removed and sensor mounted on rear hub.



    The top plate then screws to the gearbox and onto a piece of square tube that then is attached to a Cortina gearbox mount for a Type 9.



    These then bolt to a rectangular cross beam that is bolted to the chassis cross member (I bolted it right through into the cabin to be safe)





    Gear stick look in the right position, may look at adding a long gear knob or an extension as it is currently quite low (note hand brake has been shortened by about 1" from stock). (m10x1.25 I think, hhttp://www.ebay.co.uk/itm/4-M10x1-25-Aluminum-Shift-Knob-Extension-For-Manual-Gear-Shifter-Lever-Extender-/112002160992?hash=item1a13d95960:g:nCUAAOSwiwVWTbrB)



    I have ordered a special clutch cable (Escort Mk2 pedal box with gearbox end adjuster) from Speedy Cables which will hopefully be here in a week or so. Will post some pics when this is in and working (pulling from the rear).
    Last edited by ugg10; 07-11-2016 at 22:17.
    1968 Ford Anglia 1.7 Puma engine/Escort front/5 Link rear/RX8 box
    http://www.Anglia1968.weebly.com

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    Re: Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    Ok, so I got my gearbox in and found that the clutch arm was almost at it's furthest extent when the clutch was out i.e. left no travel to depress the clutch.

    So, spent today removing the box so I can do a measure up and see what I can do about it.

    Here's what I found -

    Setup - RX8 6 speed box with standard clutch arm and spigot bearing (converted to cable operation instead of hydraulic)
    Puma 1.7 Zetec SE with standard flywheel, standard clutch cover and Pinto 215mm clutch plate
    Adaptor from Freddy

    Measurements -
    Gearbox - Mating surface to release bearing front face - clutch arm forward - 82mm, clutch arm depressed - 55mm
    Engine - mating surface of adaptor to clutch cover fingers - 60mm

    So, looks like I was correct in that the release bearing was almost fully depressed when only just touching the cover plate (5mm of movement left).

    So, options, make up a spacer or move the pivot point forward.
    The latter is the easiest so just used a M10 bolt ground over the head and used that with a locking nut to move the pivot point about 15mm forward. Now release bearing sets just over 60mm from the front in resting position.

    Will try and get the engine and gearbox back together tomorrow and see how it looks.

    Pic of the new pivot bolt with the original.
    1968 Ford Anglia 1.7 Puma engine/Escort front/5 Link rear/RX8 box
    http://www.Anglia1968.weebly.com

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    Re: Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    Quote Originally Posted by ugg10 View Post
    Ok, so I got my gearbox in and found that the clutch arm was almost at it's furthest extent when the clutch was out i.e. left no travel to depress the clutch.

    So, spent today removing the box so I can do a measure up and see what I can do about it.

    Here's what I found -

    Setup - RX8 6 speed box with standard clutch arm and spigot bearing (converted to cable operation instead of hydraulic)
    Puma 1.7 Zetec SE with standard flywheel, standard clutch cover and Pinto 215mm clutch plate
    Adaptor from Freddy

    Measurements -
    Gearbox - Mating surface to release bearing front face - clutch arm forward - 82mm, clutch arm depressed - 55mm
    Engine - mating surface of adaptor to clutch cover fingers - 60mm

    So, looks like I was correct in that the release bearing was almost fully depressed when only just touching the cover plate (5mm of movement left).

    So, options, make up a spacer or move the pivot point forward.
    The latter is the easiest so just used a M10 bolt ground over the head and used that with a locking nut to move the pivot point about 15mm forward. Now release bearing sets just over 60mm from the front in resting position.

    Will try and get the engine and gearbox back together tomorrow and see how it looks.

    Pic of the new pivot bolt with the original.

    Looking good can't wait to see it all up and running now!

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    Question Re: Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    I just came across this thread, I'm doing a conversion right now and need an adapter, I'm wondering how this worked out and is one still available?

    Thanks - Cris

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    Re: Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    Which engine are you going to use?
    There is a zetec se to rx8 plate and it's made by a guy called Freddy who's on here. Not sure about the others.
    Someone will correct me if I'm wrong but I believe the duratec is a joint venture between ford and mazda so might fit without any adapter

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    Re: Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    There are three ford gearbox patters in the i4 family -

    “normal” Zetec - 1.6, 1.8, 2.0 silver tops, 1.8, 2.0 black top and ST170 badged Duratec but actually a Zetec. These all have the old ford bellhousing pattern so the same as xflow, cvs and pinto so type 9 will bolt straight on. Steel block and alloy head.

    Zetec SE - joint venture between ford and Yamaha, all alloy block, 1.25, 1.4, 1.6 and 1.7vct. Different bellhousing so type 9 needs a bespoke one (retro ford). 1.7 has a small spigot bearing cavity in the crank which needs boring out or the gearbox input shaft grinding down. Later versions of the 1.6 with vct were badged as Duratec. Same block also used for the 1.6 ecoboost. All alloy.

    Duratec - 1.8 and 2.0 (2.3 and 2.5 available) all alloy engine. Again a different bellhousing pattern again (retroford have them). Also used in the NC Mk3 MX5 but on this engine the engine and gearbox are at an angle to each other.

    So, for Duratec you can use MX5 mk3 box that bolts on if you can deal with the angle.

    All other the RX8 is the best bet as it has a ford 1” 23 spline input shaft. Noting that the Zetec come with this clutch plate but Zetec se and Duratec need to mix and match older (Sierra) clutch plates.

    I think Fredy686868 has adaptors for all three of these engines for the RX8 box.

    Hope this helps.
    1968 Ford Anglia 1.7 Puma engine/Escort front/5 Link rear/RX8 box
    http://www.Anglia1968.weebly.com

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    Re: Zetec SE, Sigma, Duratec 1.6 to RX8 gearbox

    Has anyone got a 1.6/1.7 running the RX8 'box with a hydraulic clutch?

    So far I've got the engine, 'box, bellhousing adapter plate off Freddie and I know I'll need a 23 spline friction plate to replace the standard Puma one - will any friction plate work, provided the diameter is close to the Puma one? Thinking of just using an RX8 one if it fits, or otherwise one off a Zetec-engined car (Focus, Mondeo etc.) - let me know if there are issues with this.

    Then it's just the hydraulic slave cylinder - I've no idea with this, does anyone know which are suitable?

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