Matt's 512bhp EK9 project


Small update, my VSS drive for my Cusco lsd turned up yesterday so I can finally take the box off and rebuild it with the mfactory/syncrotech syncros and the plated diff.......going outside to take it off lol.

 
Well the box is out, about 2.5hrs on my own with a couple of rain showers thrown in the mix. Note to self, take the Intermidiate shaft off next time as it was a right bugger to get off with that still on.
 
I see you struggled with the bitch pin lol

Plated diff will make a nice difference on the road
 
Buckyy said:
I see you struggled with the bitch pin lol

Plated diff will make a nice difference on the road
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I didn't even bother trying to knock out the bitch pin lol! Stuggled with that far too many times in the past so i just undo the linkage now haha!

Hopefully starting the box rebuild tonight.
 
So I stripped the box down last night with my mate Marc. Turns out my box uses the older taper roller bearing design, this is because it's a very early 97 EK9, I'm sure from 98 on the offset ball bearing was used on all models. This means I need to convert it to a ball bearing style diff, with the bearings on the diff we placed it in the housing and measured the gap and selected the correct shim for the correct clearance. Turns out I need a 1.35mm shim so that should be here in 2 days.

The rest of the box was tired, I was having real issues coming down the box from 4th to 3rd. Upon inspection we found 3rd-4th and 5th-reverse synchro sleeves to be badly worn. Luckily amongst my boxes of crap at home I had some spare from a job lot of parts I acquired years ago, these were like new so went in. On went the carbon synchros and new bearings and seals throughout. Just waiting for my shim to turn up now before it can go back together.
 
So the box is all back together, every bearing/synchro and seal replaced, new diff in and shimmed to spec (0-0.1mm). Back together and bench tested, all ok.
Can't thank my mate Marc enough for the help with it! Just need to get it back in now once this rain stops!
 
Wow, what a car. Really enjoyed reading the thread.

Also watched a couple of your in-car vids, you're a pretty handy driver :nice:
 
Sparrowhawk said:
Wow, what a car. Really enjoyed reading the thread.

Also watched a couple of your in-car vids, you're a pretty handy driver :nice:
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Thanks dude! It's been a love hate relationship over the years but aren't they all lol!

Please keep up your good work, loving the race reports and your enthusiasm, shame about the clutch last time out:(.
 
So the gearbox is in thanks to a lift from @MadM1ke87. Road tested and omg! What a difference the diff/synchros and the 225/45/16 R888R tyres make, the power on turn in is unreal, can upshift through bends that I couldn't before. It bangs a bit at low speed but hey ho, not the end of the world lol.
 
Brilliant thread mate, with all that happened to you it never got you down you just rebuilt the car bigger and better. :bow::bow::drive:
 
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