Gary's Track Day/Fast Road Weekend Car 1zz Turbo.. Now Built 2zz Turbo with E153

[Gaz2405]

No prices yet.

Easiest way is to use the MWR flywheel.

If not you'd be I to custom clutch discs.

Cross member tbc as I've not got mine fitted yet, but from taking measurements of both boxes mocked up I don't think so.

[Nvy]

No prices yet.

Easiest way is to use the MWR flywheel.

If not you'd be I to custom clutch discs.

Cross member tbc as I've not got mine fitted yet, but from taking measurements of both boxes mocked up I don't think so.

Waiting on your progress:)

[Gaz2405]

Project took a little side step yesterday.

New flywheel has come, however it's designed for an MR2 turbo clutch, (which I thought I had)

It turns out the clutch and flywheel combo I have are specifically designed for each other. 

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I need to drop of the MR2 for th next couple of weeks as I've got some work to do on th campervan.

That's needs a new sump and alternator (axle out job!)

 

 

[Gaz2405]

Bits didn't arrive for the campervan, so the car got a few hours.

MWR flywheel on.

Stage 3 competition Clutch for th E153. Rates to 450bhp, but the torque a 3sgte pita out at that is way more than I'll be producing so should be good for what I need.

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Just currently wrestling the gearbox into position.

McIver style pulleys and straps!   

[Gaz2405]

Gearbox is now on. Finally!

Had a nightmare.

Gearbox was fowling on the subframe, so no I decided to drop the subframe to make it a little easier.

My method of fitting the adapter to the gearbox first was incorrect, it wouldn't go over the flywheel tabs for the clutch.

So gearbox off, clutch off and flywheel off. Adapter plate off gearbox and onto engine.

Refit flywheel and clutch.

Try to fit gearbox..... Boom fits.

Just got a few holes not lining up 100%


I think it's because the clutch plate isn't  100% in the centre, so it's pulled to one side slightly,  othing a bit do brute force won't sort. It's only a few mm out, but I don't just want to go he'll for leather with the impact gun and knacker the threads up.

[puma2]

sounds like a good fight hopefully turn out all good

keep going it will all be worth it when up and running      

[Gaz2405]

An hour this morning and the gearbox and engine are now fully mated together.

That'll do for today. Garage tidy up later.

[Gaz2405]

Started on welding the passenger gearbox mount.

Getting brave now letting my welding do important stuff 

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Whilst it may not be cosmetically amazing, it should do the job just fine. (He says...) 

[Gaz2405]

I got half a day on the car today.

2nd mount made up.

Driveshafts in, gearbox topped up.

Testing the theory before it all goes back together properly.

Lumpy idle as an O2 bung is out, oil drain was a temporary fix as it was clashing with the bearing carrier.

She started 1st time after about 2/3 months out.

[T4YLR]

Hi mate! Loving the build saw it from YouTube just a quick question about your OG 1zz turbo build I'm looking to go the same with a Saab Turbo fit for Saab TD04HL-15T just wondering what you used to the exhaust flange? Was it a v band adapter from the turbo or did you use something else?

[Gaz2405]

Hi mate! Loving the build saw it from YouTube just a quick question about your OG 1zz turbo build I'm looking to go the same with a Saab Turbo fit for Saab TD04HL-15T just wondering what you used to the exhaust flange? Was it a v band adapter from the turbo or did you use something else?

Hi buddy I've still got the down pipe knocking around some where.

I'm away at the moment let me have a look when I get back. It was a 3 bolt flange effort.

[T4YLR]

Perfect! just looking on eBay and can't really find much found a 'universal' 3 bolt to vband and just unsure if it'll fit, would appreciate if you get a chance to have a look

https://ibb.co/kqDrgKq

[Gaz2405]

Long time no update, been busy with life and other stuff.

Anyhow, I was buggering around trying to get the gear linkage working.

It was mega faffy, welding, measuring, drilling welding.....you get the picture.

I just couldn't get it to sit in 2nd and 1st gear properly.

So I contacted MWR to see if they'd sell me the bra let they make in their kit separately, after a few emails a deal was done and after 3 days it arrived on my desk at work whilst I was on holiday.

Finally back I'm the UK, I banged the bracket on, it came with all the bolts needed and a cable bracket too.

Fair play MWR.

It was till struggling to get into 1st and 2nd.

I'd done exactly what it said in the manual, swap the turbo shaft out for the 5 speed mr2 roadster item.

I took the shaft out and compared the two,there was a small cut out on one of the selector fork/tangs on the GT4 item.

Somi took the roll pins out and swapped that onto my shaft. We're talking 5mm cut out/step if that.

But that was the way the mechanism was wanting to go and it felt like it had some resistance and what did I have to lose?









Turns out that was all it needed!

I now have fully working gear selection!

Over the weekend I'll bang the new race arms in and get her back on 4 wheels and hopefully have a test drive!

[Gaz2405]

Insurance renewal today.

Changed to Sterling from Reis as I didn't renew in town with Rei's and they're just going through new underwriting policies, so not taking on new business.

£322 fully comp, upto 500bhp, everything and more declared.

Being 40 has its uses!

[Gaz2405]

After nearly 3 months the car just pulled itself out of the garage under its own steam.

E153 gearbox conversion. Completed it mate.






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There was some mild panic when the gears wouldn't engage, but a quick adjustment of the clutch pedal and we were sorted.

Next job is to swap the alternator out as that's given up the ghost.

Then let's see what we can really do with this thing without the gearbox holding us back.

[Nvy]

Did you have to modify the x member?

[Gaz2405]

Did you have to modify the x member?

It needed some "massaging" with heat and a big old hammer.

[Gaz2405]

First day testing this evening.

It's always with trepidation after the car's been in a thousand bits!

Firstly all gears change smoothly and as expected, 5th to 4th takes some getting used to.

Quick drive up the road to check for leaks and I noticed my alignment was horrible, nipped back home and luckily because I've now fitted by adjustable arms the mega toe in that I had on the NSR was sorted within minutes.

Back and and blew a boost hose off, reattached at the side of the road.

Time to give it some beans.

The cars just taken plenty of 26 psi pulls for around an hour and all is good.

I think I actually prefer the short ratios compared to the old box, 60mph in 2nd at around 7200rpm, 80mph at 3kish.

The box suits it much better for a B road blaster, I may play with the springs in the selector shaft to make it spring back to center a little more than it currently does.

Just got a small weep from where the gearbox oil cooler lines enter the box (I did think I might get one as I'd forgot to put rubber O rings on).

The car is officially back and boosting!

[jvanzyl]

Awesome news man, well done!

[puma2]

 :)all this work and now its out for fun time  
nice one lets see some good pictures now and enjoy your hard work  

[Alex Knight]

Great work that man.
Looking forward to seeing a video at full boost.

[Gaz2405]

Great work that man.
Looking forward to seeing a video at full boost.

Draggy has been ordered. 😂

[Gaz2405]

Had a few minor niggles I needed to sort out on th car.

New alternator and gear stick wasn't returning to centre properly.

Gear stick issue ......when I got my E153 box it didn't come with any bolts/cover for the selector shaft housing so I just reused my C series stuff as they fitted.

Turns out the one at the rear of the box, is the detent lock bolt and is responsible for bringing to gear lever back to centre.

The C series one isn't long enough.

So on the phone to Toyota, tha part is discontinued....bugger.

It was only by chance the Paul Woods mentioned the S54 used the same part.

A quick call to Andy at Jspec and one was winging it's way to me on the house.

Fitted in 5 minutes and were sorted.


This is the part ^^^^^

Next up alternator...I'd been getting a low voltage reading on and off since the day the gearbox died.

Now I'd previously thought I'd dropped the alternator out of the bottom of the car, turned out I hadn't and it wouldn't fit.

So off with the engine mount, now I must have rattled one of the nuts on too hard last time as I was stuck with one that was just spinning.

Luckily enough room to get a grinder in and put a star in the top of it, the chipped the bits off.








Once that was off, it wasn't exactly straight forward, oil cooler set up was in the way slightly, undid the top hose off the cooler and bent the bracket to make space.

All back together and a quick start up to check for fluid leaks.......

30 seconds later half a litre of oil on the floor.

Turns out when I'd push the oil cooler out of the way, the bottom hose had pushed against the fire wall and undid itself a quarter turn.  With that nipped back up I drenched the back of the fire wall in brake cleaner and cleaned up underneath.

Next up is a test drive and an MOT.

[Joesson]

@Gaz2405

I've mentioned the power of persistence several times on here and you've confirmed my thoughts about this very useful "tool".

[Gaz2405]

I might need a bit more persistence soon!!

Changed out my short throw shifter back for my standard one as I prefer the feel.

Took it out for a drive, first big pull in 2nd and lost all drive at about 6k.

Thoughts going through my head...

"It better not be the f#cking gearbox!, I cannot be arsed taking that out again"

I've yet to take the hub off, but I suspect I've stripped the splines I'm the hub in the near side as the shaft is just spinning. Either that or CV joint.