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Lotusfab

Esprit Turbo project car - part3 - the further continuation

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The good ideas on this blog are costing me a fortune! Two new tensioner springs on the way! 

I am tempted to have a go at rebuilding the gearbox myself. The manual is quite comprehensive. Any thoughts? 

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The engine is nearly there just painting the covers in crinkle black.  Then an oil prime and the timing belt. I want to prime the oil first so I can rotate the pump and confirm it generates oil pressure before the rest of the timing belt is on. I also have to rebuild the tensioner as I am now paranoid about the springs. Of course the earth strap has to go on! Anything else that's needs attention whilst I'm busy bankrupting myself? 

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1 hour ago, Lotusfab said:

am tempted to have a go at rebuilding the gearbox myself. The manual is quite comprehensive. Any thoughts? 

I've done it, it's just a gearbox....  In fact the box in my car is currently being run in at the mo after a rebuild.   Nothing particulary complex.    The issues you will face are:

  • Whatever chipped that gear may have caused further damage
  • The availability of parts is limited (expensive)
  • Some parts are now obsolete - one of the bearings I recall (The gearbox specialists have developed alternatives)
  • There are a number of parts that require particularly accurate measurements (Pinion height probably being the most exacting)
  • You will need to go through another shimming pantomime until its correct
  • A few special tools are required, but nothing that cant really be manufactured or worked out 

Previously, I would have recommended a good 2nd hand box as a cheaper approach, but these dont crop up as often as they used to.   As a first option I'd maybe suggest getting a quote from Alan Voights to fix yours, then decide.

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Thanks Steve, still,considering what to do. I would use like to see all of the parts inside the bell housing end as well before as decide. It seems pretty simple,  but we all know it's easy to say undo a bolt and it turns into days or weeks of trauma. 

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Hi Tim, yep saw that and I'm reluctant to pay £300 especially with the amount this has already cost. I have found some used ones so may go down that route.

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".... this car has probably more new parts on it than any other."

Speak for yourself, but I'm not so sure of that statement @Lotusfab

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I know of a number of Esprit restorations that have exceeded that amount by a long way. Virtually all of them undertaken by their owners, with minimal professional restoration assistance, but with similar and sometimes greater levels of attention to detail. In many ways they are total nut (& bolt) jobs 😀

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I took the amount off, but it was a year ago without the interior and I have done a lot of work since then. It's real scary. The  thing that has pushed this up there was making it a Bond car. The extra parts and bespoke services have taken a toll on the budget. I still havn't built the ski racks!  Never mind I shall enjoy driving car. It's not all about the money! A flick back to the start of this blog it's quite scary at the number of parts needed. The Turbo far outstrips the S1 in parts, nearly every system is far more complex.

Here's the straw that broke the camels back!IMG_6627.thumb.JPG.900a432879e9a4b95a039ceb32e80ac7.JPGthe tensioner spring.....

but there have been a few larger straws!

IMG_6191.thumb.JPG.f40e58dc2cd42a39ec21d781f6debc89.JPG

😩😩😩😩😩😩😩😩😩

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34 minutes ago, Fridge said:

I know of a number of Esprit restorations that have exceeded that amount by a long way. Virtually all of them undertaken by their owners, with minimal professional restoration assistance, but with similar and sometimes greater levels of attention to detail. In many ways they are total nut (& bolt) jobs 😀

Sorry, yep to be fair I know if some others that are stunning. I'm busy feeling the pressure of 5 years of Bond restos! 

The cost if those mirrors was eye watering! 

Onward! 

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4 hours ago, Lotusfab said:

Sorry, yep to be fair I know if some others that are stunning. I'm busy feeling the pressure of 5 years of Bond restos! 

The cost if those mirrors was eye watering! 

Onward! 

Attaboy, Fabian! My S2 resto outlay has well exceeded the purchase cost of the car and there's yet a shedload of cash required to complete. Went with an HML upgraded gearbox rather than chance the state of my long idled original, by the way. When my classic Elan was sold in the '90's the recap was perhaps 2/3 of what I'd put in. The grand memories of my time with that car easily outstrip any concern for what was spent.🙂

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I hope to be flying along in this one day! That's why I won't be beaten by a gearbox. Thought I'd time myself for fun  1 hr 44 mins in!IMG_6633.thumb.JPG.351191933f4b9a96e5434156ce546c42.JPGIMG_6635.thumb.JPG.06a94c72bc823fc067e5864847f4174e.JPGIMG_6637.thumb.JPG.776d39372590fe0ad5047d53e830f06e.JPGIMG_6639.thumb.JPG.a4d165abecfbf8a560a63abec264c1fb.JPGIMG_6645.thumb.JPG.cf9e2e8b73c222e1028503f1d9f09bc2.JPGI always know where the previous owner has been as he leaves me a trail of RTV! He's been all Iover this. Lots of new bearings but a sloppy job missing the gear, unless he assessed it as ok, because only a slight part of the tooth is damaged? Pretty simply to get here when I compare it to the work on the Landrover Discovery, that things like a truck. This is like a toy in comparison. You do need a breaker bar to get the sincro bolt off. But on the Disco we're talking serious torque at least two times as much on a suspension bolt! 270NM! Some you can't undo you have to angle grind the suspension off!  Lock the gears by engaging two and this bolt is easy to remove in comparison. 

I have got pretty lucky. As you can see the driveshaft bearings are new, as are some of the others. It feels smooth. I'm not  brave enough to run this with a chip so I'll continue and replace the pinion. 

Happily the diff and other bits are in stunning order. The drive shaft bearing in the housing not so much, maybe he didn't have the tools. I'm thinking of having some tools made so this won't be an issue ever again.

Now to get the shafts out! 

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Of course it's easy to take anything to pieces, the real skill is how it goes back together. I've a feeling this gearbox will require some precision equipment and a lot of thought,! 

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Anyone know the nut sizes of the speedo Nut and half shaft nut? I think the half shaft nut maybe 46 mm.

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1 hour ago, Lotusfab said:

Anyone know the nut sizes of the speedo Nut and half shaft nut? I think the half shaft nut maybe 46 mm.

DF665410-8872-4C19-B356-136B63AA3C0A-large.jpg

Just measure them ...  

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 Was hoping to compare. The half shaft nut is difficult I believe it's 46 mm,  the speedo one is about 36 mm, but I IMG_6644.thumb.JPG.26f0b624fbcfa2d064e35c3c0b99f84e.JPGwanted a cross check.

Has anyone seen this disc before in their gearbox? It's not on the parts manual as far as I can see.

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On boxes I have worked on, the gear itself and the synchro dogs and cone are all machined as one part. But looks like on this they are separate parts. But the whole thing including the baulk ring is listed as one part in the book which presumably includes that shim.

Seems to be to limit the movement of the synchro hub which makes sense if the shaft movement itself is not limited.

 

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It looks newer than the other parts. Would be nice to confirm it’s correct.

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Thanks Andy, have checked the new bearing picture and the disc/shim is correct.

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3 hours ago, Lotusfab said:

The half shaft nut is difficult I believe it's 46 mm

I'll measure my 'special' box spanner tonight if you still need it.  I recall you are correct with the 36mm 'nut' securing the speedo drive 

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When I got my S1's Citroen gearbox overhauled it required a thin 36mm spanner to undo something inside. I can't remember what, as I had the item restored professionally.

The special Citroen tool was unobtainable, but the transmission specialist was able to thin down this tool easily and continue the work:

https://www.ebay.co.uk/itm/Land-Rover-Defender-Discovery-Td5-Tdi-Td-N-A-V8-Viscous-Fan-Spanner-32mm-36mm/230620797702?_trkparms=aid%3D222007%26algo%3DSIM.MBE%26ao%3D2%26asc%3D20190212102350%26meid%3D6fe4222274a44a5da8e30125e00cea28%26pid%3D100012%26rk%3D3%26rkt%3D4%26sd%3D142246694013%26itm%3D230620797702&_trksid=p2047675.c100012.m1985

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