When you know you've got an MR2 engine hoarding problem!

3x1zz 2x2zz's

Forgot I had a spare 2zz that was stripped down, made it miles easier to try the E153 bell housing adapter.

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Engine and Gearbox in holy matrimony.

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I've just used whatever engine to trans bolts I had knocking around to test the theory.

Adapter plate bolts to the gearbox first and then it gets offered up.

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Look at the lovely precision machining around the transfer case cover.

Also got the GT4 shifter mechanism swapped out for a 5 speed jobby.   

I'd you look closely at the block you can spot the splits)cracks between the cylinders.

Next task is to measure and tot up the correct bolts I need to do the do properly

And for all their asking about weight.

59.3kg

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Plus probably another 2-5kg for the bigger axles.

Old gearbox out tonight.

Made it hard for myself by not removing any boost pipework, and also didn't remove the top gearbox mount I just slipped the long bolt out.

Just makes it tighter than it should be.

Anyway felt alive after wrestling it off my chest!

Weighed it...

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43.9kg with the top mount still on.

So only a 15kg penalty in weight terms I don't think that's too bad.

Took the end cap off the gearbox and found 5-19 bits of third gear in there.

Then realised I didn't have a bearing puller to get the rest of the box apart.

All in all a good couple of hours getting filthy!

Adapter plate in CAD.....flywheel next.

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Any chance you can share these files if you cant find someone to do it for cheap? I can ask the local guys to do these for anybody from the forum and I hope we can stay under 1000 quids for both.  Also do you know if e351 has the same bolt pattern? I am looking at it as I want "conservative" 350-400 hp

Yeah no probs, E351 had a different bolt pattern apparently.

I am test fitting my turbo and it seems that it is where yours is. Do you have pics of your oil return?

Quote from: Nvy on June 13, 2023, 17:16I am test fitting my turbo and it seems that it is where yours is. Do you have pics of your oil return?

I'll grab some, but pretty straightforward really.

Quote from: Gaz2405 on June 13, 2023, 17:19I'll grab some, but pretty straightforward really.

Yeah but with the oem sump it looks a bit far from the place where TTE kit suggest to drill.

I drilled the sump as high up as I could get it.

Quote from: Nvy on June 13, 2023, 17:16I am test fitting my turbo and it seems that it is where yours is. Do you have pics of your oil return?

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Dodgy sump photo, drive shaft runs above the curve. Sealant on th sump is a safety precaution as it's a threaded sump fitting.

So the conversion took a big step forward today.

I ordered a Celica ST185 outer CV.

I can confirm it fits both the turbo driveshaft and indeed the Roadster hub!

Boom.

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Why MWR don't tell people this I'll never know, I'd have gone for an E153 kit ages ago if I knew I could use standard turbo driveshafts and different CV joints and all I had to do was worry about the mounts.

As they sell a bell housing plate and flywheel for under $1000.

Bonkers.

Anyway I'll order another outer CV now I know they work.

Taken a few more bits off my C66 like bungs and reverse sensor etc for the E153 and added some AN fittings for the oil cooler.

Just waiting on a set of bolts then it's show time!

I also think I've found an easy way of butchering to two different bearing carriers to make them work as one.

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Dodgy sump photo, drive shaft runs above the curve. Sealant on th sump is a safety precaution as it's a threaded sump fitting.

I think the situation looks a lot like mine. The oil drain is about 17 cm away from the block and about 12 above the shaft. I think its going to work, what are your thoughts?

Quote from: Gaz2405 on June 13, 2023, 19:13So the conversion took a big step forward today.

I ordered a Celica ST185 outer CV.

I can confirm it fits both the turbo driveshaft and indeed the Roadster hub!

Boom.

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Why MWR don't tell people this I'll never know, I'd have gone for an E153 kit ages ago if I knew I could use standard turbo driveshafts and different CV joints and all I had to do was worry about the mounts.

As they sell a bell housing plate and flywheel for under $1000.

Bonkers.

Anyway I'll order another outer CV now I know they work.

Taken a few more bits off my C66 like bungs and reverse sensor etc for the E153 and added some AN fittings for the oil cooler.

Just waiting on a set of bolts then it's show time!

I also think I've found an easy way of butchering to two different bearing carriers to make them work as one.

Well done, ill look into e351 after my box is danzo. With the template above I can measure things and line up bolt holes easy.

Waiting for parts now so getting the rest of the mounts drawn up.

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Bolts got delivered today.

So I've now got all brand new 10.9 Allen head cap bolts for the engine to trans and adapter.

Mix of M12 and M10 1.25 thread from 25mm to 50mm in length.

Back home all bolted up nicely apart from one bolt that's been a bit of a bugger, it's an M10 that a could redrill and tap to M12 but we'll see.

As part of the conversion you've got to use a 5 speed shifter and MWR sell a bracket in their kit.

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So I got on with bodging my own.

Cardboard aided Design to test the theory, then I get it cut and welded.

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Following on from a comment from Paul Woods on the Facebook group about the driveshafts needing a spacer where it goes into the hub using the st185 CV joint.

I set about having a good look and measure tonight.

I think I noticed straight away was the abs ring being bigger on the ST185 and not being anywhere near the pick up, infact it wouldn't even seat properly.

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By a stroke of luck the CV's are near identical in terms of profile.

I wonder if my old abs ring will fit....

A few little taps to get it off, some heat to expand it....

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And boom there we go, I also measured the both CV's and I cannot see where a 4mm spacer might be required. They line up exactly the same.

Maybe th older st185 didn't share the same out she'll as the new ones.

Anyway both drivershafts now made up and a sheet of 4mm steel to make my bracket for the cables.

I also took a few measurements with th gearbox mounted to by spare block and it doesn't look like I'm going to need to cut the subframe.

I do think this is only a V6 issue and not e153 on a 1/2zz.

No pictures today, but another milestone.

Carrier bearing bracket made.

Used the original 2zz item and cut it down flat, cut the end of the turbo one and welded them together.

Then spent the r at od the day getting frustrated at trying to sort the gear linkage brackets, they're so fiddly!

I'll have another crack at them throughout the week.

Got an hour on the car this evening.

Managed to get the gear linkage sorted.

New bolts will be ordered, and another mounting point added to the cable holders.

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Next up was the take the old flywheel off and get the new one on.....

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Spot the difference....

It's a 1zz flywheel. Insert facepalm.

I'll be onto some machine shops tomorrow to get some quotes!

Got too impatient.

Ordered a new flywheel from MWR.
 

Progress has been slow of late, haven't touched the car for a while 5 days 

New 2zz flywheel from MWR should be here on Monday.

Hopefully I can then get the whole thing in the car.

Plan is to get the engine and box on the East and West mounts.

Tack weld the laser cut mount plates together and take them into work to get done.

Whilst I'm pretty confident at welding I don't spend enough time doing it. And for a few beer tokens I can have them welded by a coded welder at work.

I'm just about there with the conversion kit too to offer for sale.

It will consist of:

Bell housing adapter plate and all three mounts laser cut.

You then buy your own flywheel from MWR either 1zz or 2zz.


I'll also provide part numbers required for the outer CV's and instructions on how to sort the gear linkage and bearing carrier.

What about other tranny options? I dont think 3.5k gearbox is on the list for the average Joe.

E153's can be picked up for less than a grand?

Quote from: Gaz2405 on June 25, 2023, 13:44E153's can be picked up for less than a grand?

Havent seen any of those for such low price. Got some questions:
Do you have any prices for the kit?
Will the normal 1zz flywheel work?
Do we need to modify the cross member?