Trigger Posted September 7, 2009 Share Posted September 7, 2009 Not sure "where" to put this? but thought it would be good to have it here for anyone looking to do this swap/convertion in the future and so no-one else will fall into the same problems I did... When fitting a Sigma 5 speed gearbox into an Ex lancer there are x2 choices: - cut a hole in the floor/tunnel (about 2inches) further back for the Sigma shifter to come up through - or swap the Sigma extention housing with a L200 housing so the shifter is in the "factory" location (meaning NO cutting needed) All this is because the Sigma shifter (gear stick) sits further back than the Ex shifter, aswell as having to cut a hole further back in the floor/tunnel you'll have to "trim" back the centre console trim (if still using it) so it all lines up with the Sigma shifter I went with swapping the extention housings over (rear half of gearbox) so no cutting required and looks factory still NOTE: Sigma and Ex have the SAME driveshaft uni (size and splines) but the L200 is BIGGER and having more splines, (because the L200 has a bigger output shaft) So I had to get a "custom" tailshft seal made up, with an outter diameter to fit into the L200 extention housing and the internal diameter of the Sigma/Ex driveshaft uni to seal against it For a month or so, I drove around with the Sigma box/L200 extention housing with constant OIL LEAKS! I "thought" it was just the tailshft seal leaking, but after changing the seal x2 times, it turned out to be the "internal bush" in the L200 extention housing which is BIGGER than the Sigma, leaving the driveshaft uni "flopping" around in the extention housing (causing oil to get past and leak on to my garage floor) Smaller (Sigma) tailshaft on the LEFT: I compared a Sigma and L200 extention housing "side by side" to check for any differences, to find the only difference between the them was the rear internal bush! (note: the Sigma housing is on the RIGHT) So It was a case of "working out" what parts I needed for it ALL to work... - L200 shifter (to be in the factory location) - Sigma extention housing (for the smaller internal bush, and NO oil leaks) Difference between L200 (TOP) and Sigma shifter shafts: LONGER = Sigma Then just a case of using the L200 top plate/cover (shorter of the two) Complete Sigma box (with "some" L200 internals) Quote Link to comment Share on other sites More sharing options...
lowlancer Posted September 7, 2009 Share Posted September 7, 2009 Prime knowledge Can a mod please add this to the mitsy tech thread? Quote Link to comment Share on other sites More sharing options...
rwdlancer Posted October 12, 2009 Share Posted October 12, 2009 trigger,do you still have your spare l200 extension housing and possibly do you want to sell it? Quote Link to comment Share on other sites More sharing options...
Trigger Posted October 12, 2009 Author Share Posted October 12, 2009 Yip, and yip Quote Link to comment Share on other sites More sharing options...
rwdlancer Posted October 13, 2009 Share Posted October 13, 2009 oh yesssss.il pm ya Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted May 20, 2012 Share Posted May 20, 2012 Hey Trigger Sorry for bugging you. I found the write up but for the life of me I dont know how the shifter rod comes out. Ive got the whole extension housing off and by the looks of things the shifter brackets on both ends of the rod are attached by grub screws. No matter what position I have the shifter rod I cant get at these grub screws. Pics Am I missing something really simple? Quote Link to comment Share on other sites More sharing options...
Trigger Posted May 20, 2012 Author Share Posted May 20, 2012 All good man, Yea have a close look at your 2nd pic You need to punch the pin out to realise the shifter rod (you'll need a punch smaller than the pin and knock it out) Let us know how you get on... Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted May 20, 2012 Share Posted May 20, 2012 Is the pin splined? Cos ive been hitting it and it doesnt seem to move. Quote Link to comment Share on other sites More sharing options...
Trigger Posted May 20, 2012 Author Share Posted May 20, 2012 Na man, It will/should come out one way easier than the other Just hit it! Quote Link to comment Share on other sites More sharing options...
ex lancer wat! Posted May 20, 2012 Share Posted May 20, 2012 did your shifter have a plastic cup/shifter bush on the ball of your shifter? after one of thoses cups, know how i would get one? Quote Link to comment Share on other sites More sharing options...
OSM Garage Posted May 21, 2012 Share Posted May 21, 2012 I asked that question too viewtopic.php?f=1&t=22374&hilit=km132 In that thread there is a part number for it fro Mitsi. I never pursued it. Quote Link to comment Share on other sites More sharing options...
Barnz.NZ Posted May 21, 2012 Share Posted May 21, 2012 Hey Damian if you're still having trouble getting pins out I found it real easy to remove speedo drive and punch pin out with pin punch going through speedo drive hole.pins are slightly tapered from memory Quote Link to comment Share on other sites More sharing options...
Ogre Posted May 21, 2012 Share Posted May 21, 2012 ^this is how i ended up doing mine too, seemed to come out easier.You do have to get the mash on tho, they are tight buggers. Also plastic bit for shifter is still available new. Quote Link to comment Share on other sites More sharing options...
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