woohoo my car lives again and I got something new

 

As one who will be doing this (or having it done) soon, what advice or parts should I have on hand that might not have been mentioned in the TSW "how-to"?

 

S shifter cables...S flywheel bolts....S clutch plate bolts...

 

Is it the CD on the passenger seat?

 

I also posted this in the other thread: the one started by txwerks for the guide they wrote on it.

The guide mentions the serial # for the tranny you want, the later one, has BKE in it. The earlier ones have BKA... well mine just got here and it's BKD. Where would that fit in? Anyone have any idea?

It should be the earlier one. I'm going with it to save costs... it was much cheaper than any others I could have gotten.

 

Posting twice again... there's 2 Getrag swap threads going.

What about the special tools? The dealer wanted well over $500 just for the 4 tools mentioned in the guide. Anyone have some I can borrow? Are they necessary? I mean, is there a different way to align the clutch instead of their $165 alignment tool?

I've never done any of this before and just find it odd that I'd need a special tool to align a clutch - doesn't it just fit?

Anyway... anyone have the tools they got for their project? Wanna loan them out? I'd pay shipping obviously.

 

OMG!! it's getting ugly!

Got through the disconnecting the steering linkage this eve. I still can't figure out how to disconnect the 2 elec. leads to the power steering pump. I got one off, but can't for the life of me figure the 2nd out. Hmmm..... I think I'll have to lower the sub-frame first and then disconnect.

Everything else seems to be going according to the guide so not much to report. I guess I've worked about 5.5 hours so far (maybe), but 1 of that was jacking the car up. Never had a car on 4 jack stands before... and some of the stands were taller than the jacks

Now I've got a lot torn out, I'm thinking of all the extra stuff I should do while I'm in there. New or refreshed alternator? how about new engine mounts? New tie rod bushings? Anyway, you get my point.

BTW, how the hell do you mount the lower sub-frame to a floor jack. The jack's like 3" in dia. while the sub frame is like 3'x4'. don't get it. probably renting a tranny jack tomorrow for this.

 

I just pulled the connectors off the PS pump. The big retarded looking one just kinda came off. I dont know how that bastard works. As far as the subframe...I put 1 of my many jacks under the big round circle in the subframe and pulled it carefully out after everything was disconnected. You just have to have someone push throught the PS resevoir so it doesnt snag. The clutch alignment tool can be had at Auto Zone or local auto parts store for like 10 bucks. Its a plastic splined tool with a circular ring at the end....

 

Thanks UKSUV! I guess it's the jack on the round part for me then. more news later!

 

accidentally left my cam at friend's house. Sadly no pics.

Now I've gotten all the old stuff out. Waiting on clutch to get started in reverse. I think I'm about 13 hours in or so. Of course we had to go to the store for the tools we didn't buy before starting. If you had all the tools and didn't spend too long messing around you'd probably be 9-10 hrs in.

I'll say the impact wrench definitely came in handy removing the axle nut. Didn't have one and had to call a friend to get one. It turned an hour of frustration with a breaker bar into 40 seconds of easy (it literally took 40 seconds for both nuts) . Also used the impact for the trans -> motor bolts. I don't know how much one costs but you might be able to rent one if you don't have one already. My friend's was an electric DeWalt (I didn't know you could get an elec. impact wrench).

Lowering the subframe was cake. It's not that heavy and we just put a jack under it (did not mount jack to it) and lowered slowly. Had 1 person manning jack, 1 holding pwr steer reservoir, 1 guiding sub-frame. It was nice with 3 people, could prob get by with 2 if needed.

 

The 1/2 drive cordless DeWalt impact is awesome. Too bad it's $300.

 

And I looked at the cables last night. Looks like one cable on the S is about 1 or 1.5 inches longer. Grrrr.... So now I've got S cables.

 

Indeed....

 

UKSUV has about 4 extra sets of cables cause he couldnt make up his mind on which was which

 

It's DONE!! :D wow. what a project. and just in time... headed to MOTD tomorrow!

 

I want a ride, I'm coming up too....I am thinking of doing the same swap...

What Flywheel did you go with? clutch?

It's a shame, I already have the clutch masters aluminum flywheel and the FX300 kevlar clutch. I'll have to buy that stuff all over again when I do the swap.

 

Anyone wants to look and chat... INDI is just that: Indi blue with white.

02 Cooper Indi blue/white with racing stripes. License plate from FL says "INDI 01". don't be afraid to say hi

 

Cool, that's my car in the sig as well...can't tell from the pics, but it's black, with white stripes/silver outline. and....new windshield and tires as of today!!!

 

Nice! Black with Black wheels and tint? oooh menacing If I see you I'll say hello.

a couple of things about this install (I'll probably do a short writeup next week):

1. Definitely use an impact wrench for the hub bolts - turns lots of labor into 40 seconds of ease (might want hearing protection - ouch!)

2. there's a wire bracket that goes on the top starter bolt - be sure to install it with the starter. It took me about 2 1/2 hours to figure that out because I didn't get a pic and it had been 2 weeks since the disassemble.

3. Install the radiator BEFORE the front subframe "horns". parts of the radiator go behind them. And don't torque them down until after installing the aluminum bumper. I had to loosen them so they would move about 1/16" for the aluminum bumper to slip on.

4. I don't know how necessary it is, but the Cover Plate isn't mentioned in the guide so I don't have one. It covers a gap in the flywheel housing. I'll install next week when it comes in.

5. The guide didn't mention the Xenon levelling connector (I think that's what it is). Make sure you disconnect that and reconnect. It's at the left lower a-arm IIRC.

6. As UKSUV mentioned... DEFINITELY need new shift cables.

7. it's easy to just use a floor jack to pop the ball joints back into their carrier. Just position them and jack to apply pressure to the underside, they'll pop in and then tighten the bolts.

8. attach the sway arm bolts BEFORE the steering tie-rod ends. The tie ros got in my way when doing it the other way 'round. Of course the 'L' style allen wrench would have helped on that so it might not be as big an issue for you. And a 17mm ratcheting box-end wrench was a godsend for this.

9. I think the tranny used about 2 liters of gear oil

10. burping the air out of the cooling system took a while. Went for a test spin and overheated (almost). Then just kept running and shutting off while adding lots of coolant over and over again. Took about 3.5 liters or so i think.

11. The fill/drain plug on the S tranny is an 8mm hex hole... probably need an hex bit for a socket (and then you can torque properly too )

12. I found something else (don't remember what) that was a 6mm hex hole. You prob. want a 6mm hex socket bit too.

13. 16mm is the same as 5/8. good to know when your set doesn't include a 16mm socket . I didn't know that, but just decided to try the SAE cause the Metric wouldn't fit.


OH! And there aren't any shortcuts The guys who wrote the guide knew what they were doing. Just follow their lead.

 

Right on man glad you got it done with success and in time for the Dragon!! How's it feel to have a 6th? I know when we were cruising in UK's, I kept asking him why he was in 5th at 6k rpm's, you have a 6th gear! It took a while to register... haha



Whats up chad!?? Long time! When are you doing your swap brotha?

 

Sooner and Sooner with the recent intake swap and pulling hard till 7k rpm. Grinds into second on the quicker shifts..

I'm good man, how bout you? the family? the MINI???

It has been a long time though, must have just answered my 3rd question..YOU SOLD IT

 

Family is struggling all around but I'll shoot you a PM on all that jazz...

Yea MINI had to go, I'll explain. But I'm on the prowl for another if I can find a cheap one locally in the next month... As much as I been hangin and helpin Justin, it's drawing me back in!!

 

6th was AWESOME on the interstate. Those 2nd-3rd shifts were great in the mountains Was finished on Monday night (mostly) buttoned up a couple of panels Tuesday night, left for the Dragon on Wed. What a ride!!

 

OH, and my swap pics are here: http://www.flickr.com/photos/2812039...7617712343056/

Some of these may not mean much to you, but here they are.

 

Dang man the pics look

Sweet job and glad your happy with it!!