URGENT: Need advice/help

Gearboxes, clutches, diffs, wheels & tyres....
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Casey
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URGENT: Need advice/help

Post by Casey » Mon Jul 20, 2015 5:58 pm

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I'm desperate to get KIMI 2 (1983 S2) back on the road asap. One by one, issues are being resolved by I really need some advice on this one please.

Long story but I had to remove the transmission and then the transmission front plate - the one integrated with the clutch release guide shaft- this one;

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On removal of the plate, the main gearbox shaft end-float shim few out, completely mangled and broken :o . I'm guessing the shim cannot have been seated correctly when last installed. Anyway I've followed the Mazda workshop manual procedure to determine what shim(s) are needed;

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A-B = 0.17mm (+/- 0.02, based on lots of measurements). So, the result is the need for a shim of 0.15mm to get within spec.

The part numbers for the two shims are;

9996-36-315 (0.15mm)
9996-36-330 (0.30mm)

But I've checked with Mazda and they say the 0.15mm shim is no longer available....

My choices would seem to be;

1. Re-assemble without shim, but the endfloat would then be ~0.15mm, outside the spec of 0 to 0.10mm.
2. Manufacture a shim - fiddly but not impossible. The Shim has an OD of ~70mm, ID of ~60mm. I could cut one from some shim sheet from scratch or purchase an "oversized" shim and trim it. There seem to be places on the internet that sell shims NEAR the size, but none are exact.

If I take option 1, does anyone know the consequences? I'm guessing increased gear wear, but surely not excessive, given the very slight departure from spec?

I'd really like to get the gearbox back asap to test-drive the car and this is the current hurdle to progress.

Ant help/advice greatly appreciated.
KIMI 1 : RX-7 1st Gen "hybrid"; 1983 S2 running gear in a 1985 S3 shell, SORN'd, long term resto project
KIMI 2 : RX-7 1st Gen; 1983 S2, "identical" twin to KIMI 1, on the road :-)
Plus a 2004 Full Bridgeported RX-8 too!

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myatt1972
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Re: URGENT: Need advice/help

Post by myatt1972 » Mon Jul 20, 2015 7:51 pm

What about choice 3 ?

Ive got a scrap gearbox, I could pull the front plate off in the hope of getting a good shim, worth a try ?
Keith...

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ian65
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Re: URGENT: Need advice/help

Post by ian65 » Mon Jul 20, 2015 8:41 pm

or choice 4,
buy the bigger shim and grind it down to the right thickness using an oil stone and a micrometer
1986 Series 3 13B Turbo II
http://rx7fb.com/viewtopic.php?f=2&t=2400
1992 Peugeot 205 1.9 GTI
1975 Honda SL125 Street Scrambler

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Casey
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Re: URGENT: Need advice/help

Post by Casey » Wed Jul 22, 2015 4:11 pm

Choice 3 it is then :D

Muchas gracias to Keith for the item which arrived today in the post;
Image

I love the innovative recycling of packaging to stop it getting bent on its journey -perhaps I'll should see what it sounds like in my CD-Player before I use it :D

I'm hoping to get time tomorrow to fit the shim and get the transmission re-installed.

What a great club W(p
KIMI 1 : RX-7 1st Gen "hybrid"; 1983 S2 running gear in a 1985 S3 shell, SORN'd, long term resto project
KIMI 2 : RX-7 1st Gen; 1983 S2, "identical" twin to KIMI 1, on the road :-)
Plus a 2004 Full Bridgeported RX-8 too!

Lucky
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Location: Worthing, UK

Re: URGENT: Need advice/help

Post by Lucky » Wed Jul 22, 2015 4:13 pm

Awesome! I hate these squashy cardboard CD cases you get nowadays :lol:

Hopefully that's the cure, +1 for this being the best club evar 8-)

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Hobbawobba
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Re: URGENT: Need advice/help

Post by Hobbawobba » Wed Jul 22, 2015 9:48 pm

That's great :lol:

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myatt1972
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Re: URGENT: Need advice/help

Post by myatt1972 » Wed Jul 22, 2015 10:46 pm

Took me longer to find a way of posting it than it did to get it out of the gearbox :lol:
Keith...

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Casey
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Location: Colchester, UK

Re: URGENT: Need advice/help

Post by Casey » Thu Jul 23, 2015 10:11 pm

myatt1972 wrote:Took me longer to find a way of posting it than it did to get it out of the gearbox :lol:
:lol: :lol:

I'm really pleased to report the shim is in the gearbox and the box (plus brand new clutch and pilot bearing) is back on the car. Was not easy to get the box back in, despite careful alignment when fitting the clutch, the box just didn't want to go back the last inch or so. After much wiggling and swearing, the box did eventually drop into place; cue huge sigh of relief!

We also changed the clutch master and slave cylinders at the same time. All now bled and clutch pedal feels great, nice and light operation too. Ran out of time to put in the gearbox oil and re-install the prop shaft - hoping to do that next week as busy this weekend.

Fingers crossed I can report she is moving under her own power next week. If so, will put up some video!

Next step will be to replace the cracked windscreen (I've noted the threads on here re sourcing one) and we'll see how she fares on an MOT test :D
KIMI 1 : RX-7 1st Gen "hybrid"; 1983 S2 running gear in a 1985 S3 shell, SORN'd, long term resto project
KIMI 2 : RX-7 1st Gen; 1983 S2, "identical" twin to KIMI 1, on the road :-)
Plus a 2004 Full Bridgeported RX-8 too!

codge
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Location: South Yorks.

Re: URGENT: Need advice/help

Post by codge » Fri Jul 24, 2015 10:41 am

Testers love two things......
The owner reciting the VIN No. complete, from memory over his shoulder as he's squinting to write it.......and......YES, a red coach line.... h[b[

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Casey
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Location: Colchester, UK

Re: URGENT: Need advice/help

Post by Casey » Tue Jul 28, 2015 1:06 am

codge wrote:Testers love two things......
The owner reciting the VIN No. complete, from memory over his shoulder as he's squinting to write it.......and......YES, a red coach line.... h[b[
:lol: :lol: :lol:

Great news today, major step forward - update on my project thread http://www.rx7fb.com/viewtopic.php?f=4&t=2989
KIMI 1 : RX-7 1st Gen "hybrid"; 1983 S2 running gear in a 1985 S3 shell, SORN'd, long term resto project
KIMI 2 : RX-7 1st Gen; 1983 S2, "identical" twin to KIMI 1, on the road :-)
Plus a 2004 Full Bridgeported RX-8 too!

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