keltik Posted November 24, 2010 Share Posted November 24, 2010 I cant speak for ford boxes....but having dealt with pull clutch boxes the last few years - i noticed a few annoying things putting the push clutch box in my hatch. It also rattles a wee bit at idle. The 2 small spring clips get easily bent when removed from the old release bearing. Had to remove the box and fiddle with them to get them to hold the release bearing onto the fork properly. Theres also a steel clip on the clutch fork that holds it onto the pivot ball. It had gotten a little bent and fell out on my first install. Easy to miss. Dont know how much of this helps you as ive never worked on a ford box....but i'd imagine theyre pretty similar. Quote Link to comment Share on other sites More sharing options...
slickyddyer Posted November 26, 2010 Author Share Posted November 26, 2010 Thank You I think I know whats going on now... I'll try and explain and then try and fix! I have no free play in clutch. Very strange. Clutch fork is pushed all the way to the back of bell housing by the pressure plate teeth when bolted to motor, eliminating any free play. Looked at mates capri 5 speed conversion and his fork is in middle. The kent motor must have very different off set crank to capri. (further back) So what I'm going to have to do is space gearbox back about 5-10mm with washers or something. What a pain in the ass as I will have to make a new gearbox cross member (as bolt holes will move 5-10mm) and shorten drive shaft 5-10mm! If I had known this conversion was so difficult I would have kept my lovely old four speed *sigh* Why does everybody say this is easy and it bolts straight up when clearly its just not the case? Idiots Probably a lot easier with the pinto motors as they would have same clearances as sierras... Quote Link to comment Share on other sites More sharing options...
keltik Posted November 26, 2010 Share Posted November 26, 2010 Easier to offset motor mounts and move the engine forward 10mm? Quote Link to comment Share on other sites More sharing options...
Raizer Posted November 26, 2010 Share Posted November 26, 2010 Wait what flywheel are you using? The Kent does have a very different crank offset to the Pinto engines, if you have a pinto flywheel on there it will cause the exact issue you are having (Kent flywheels foul on the pinto block). Could the pressure plate you have be taller than the Kent one? Another way around it is to use a stock flywheel and pressure plate with a Hillman Avenger clutch plate, the 1500cc ones are 7.5" same as the Kent clutch but have a 1"/23 tooth spline center. Quote Link to comment Share on other sites More sharing options...
slickyddyer Posted November 27, 2010 Author Share Posted November 27, 2010 Wait what flywheel are you using?The Kent does have a very different crank offset to the Pinto engines, if you have a pinto flywheel on there it will cause the exact issue you are having (Kent flywheels foul on the pinto block). Could the pressure plate you have be taller than the Kent one? Another way around it is to use a stock flywheel and pressure plate with a Hillman Avenger clutch plate, the 1500cc ones are 7.5" same as the Kent clutch but have a 1"/23 tooth spline center. Im using the original flywheel mated to sierra clucth kit! This is how everyone I know has done it. But you are right, I mistakenly used a sierra flywheel first time round and it didnt work because the starter wouldnt engage with it and neither would the sierras starter dues to the offset in crank. Quote Link to comment Share on other sites More sharing options...
slickyddyer Posted November 27, 2010 Author Share Posted November 27, 2010 Easier to offset motor mounts and move the engine forward 10mm? Ah tuch'e! Good idea Quote Link to comment Share on other sites More sharing options...
slickyddyer Posted November 27, 2010 Author Share Posted November 27, 2010 I also got a spare box to see how the fork is attached. Its exactly the same. Loose as a goose. So I don't think this was the problem. Just a clearance issue. Quote Link to comment Share on other sites More sharing options...
jakesae101 Posted November 27, 2010 Share Posted November 27, 2010 this reminds me of working on a escort race car that a guy I worked for had. 4 speed straight cut box in it had a cosworth clutch or something from memory and the only way we could get it to work with the clutch difference was space it out with 4 or 5 sandwich plates. to give it the right clearance we had to get longer bolts obviously but it was rather straight forward may have been a 2L flywheel to possibly. Quote Link to comment Share on other sites More sharing options...
slickyddyer Posted November 27, 2010 Author Share Posted November 27, 2010 this reminds me of working on a escort race car that a guy I worked for had. 4 speed straight cut box in it had a cosworth clutch or something from memory and the only way we could get it to work with the clutch difference was space it out with 4 or 5 sandwich plates. to give it the right clearance we had to get longer bolts obviously but it was rather straight forward may have been a 2L flywheel to possibly. Oh ok sounds like the same thing. Im going to get my mate to order some custom engine mounts. Moving motor forward wee bit. Or might try smashing old ones up Quote Link to comment Share on other sites More sharing options...
jakesae101 Posted November 27, 2010 Share Posted November 27, 2010 this reminds me of working on a escort race car that a guy I worked for had. 4 speed straight cut box in it had a cosworth clutch or something from memory and the only way we could get it to work with the clutch difference was space it out with 4 or 5 sandwich plates. to give it the right clearance we had to get longer bolts obviously but it was rather straight forward may have been a 2L flywheel to possibly. Oh ok sounds like the same thing. Im going to get my mate to order some custom engine mounts. Moving motor forward wee bit. Or might try smashing old ones up could you slot the mounts ? Quote Link to comment Share on other sites More sharing options...
slickyddyer Posted November 27, 2010 Author Share Posted November 27, 2010 this reminds me of working on a escort race car that a guy I worked for had. 4 speed straight cut box in it had a cosworth clutch or something from memory and the only way we could get it to work with the clutch difference was space it out with 4 or 5 sandwich plates. to give it the right clearance we had to get longer bolts obviously but it was rather straight forward may have been a 2L flywheel to possibly. Oh ok sounds like the same thing. Im going to get my mate to order some custom engine mounts. Moving motor forward wee bit. Or might try smashing old ones up could you slot the mounts ? no....theyre only little. Quote Link to comment Share on other sites More sharing options...
slickyddyer Posted November 27, 2010 Author Share Posted November 27, 2010 I just read online that some people use the 2l cortina clutch kit with this box? does anybody know if the 2l cortina clutch kit fits the sierra flywheel? Maybe its smaller and will give me this clearance. It is strange that no one seems to know about this stuff. This conversion must have been done many times before... Quote Link to comment Share on other sites More sharing options...
slickyddyer Posted November 27, 2010 Author Share Posted November 27, 2010 Thinking about ditching this bigger clutch and rolling with Hilman Hunter clutch plate an cortina pressure plate now. Save a lot of hassle and still work. Just with smaller clutch. That way no change to any mounts... Quote Link to comment Share on other sites More sharing options...
jakesae101 Posted November 27, 2010 Share Posted November 27, 2010 surely you can slot the gearbox x member then theres a bit of meat on them from memory Quote Link to comment Share on other sites More sharing options...
slickyddyer Posted November 27, 2010 Author Share Posted November 27, 2010 surely you can slot the gearbox x member then theres a bit of meat on them from memory Gearbox x member is custom made. Not much meat on it. Quote Link to comment Share on other sites More sharing options...
RUNAMUCK Posted November 28, 2010 Share Posted November 28, 2010 Tell Pav that he made it wrong, and has to have another crack it it. (Just don't tell him that I said that ) Quote Link to comment Share on other sites More sharing options...
slickyddyer Posted November 29, 2010 Author Share Posted November 29, 2010 Tell Pav that he made it wrong, and has to have another crack it it. (Just don't tell him that I said that ) HAHAHA yea hell fucken spit! Quote Link to comment Share on other sites More sharing options...
pusherman Posted December 3, 2010 Share Posted December 3, 2010 hey how did it work out im just ready to start this conversion myself im planning on using hilman clutch, did you have to get custom gearbox xmember? did you have to 'adjust' trans tunnel? Quote Link to comment Share on other sites More sharing options...
slickyddyer Posted December 4, 2010 Author Share Posted December 4, 2010 hey how did it work out im just ready to start this conversion myself im planning on using hilman clutch, did you have to get custom gearbox xmember? did you have to 'adjust' trans tunnel? Haven't done it yet. Waiting for flywheel to be lightened and clutch plate from a sierra 1600 to arrive. Should be sweet next week, I'll let you know. Had to make crossmember. Na didn't have to adjust tunnel in mk2 cortina. Just grind a wee bit round back of gearstick hole. Quote Link to comment Share on other sites More sharing options...
Raizer Posted December 4, 2010 Share Posted December 4, 2010 clutch plate from a sierra 1600 Which is the same plate as the Hillmans which most BNT/Repco's etc would have on the shelf... Quote Link to comment Share on other sites More sharing options...
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