My Essex V6 Transplant

[limitedblack]

Get one of those cheapo yoga mats, thin foam ones.

[Leeday]

Gearbox finally out:



Flywheel and clutch all intact and fully bolted to engine, so no probs there:



Output shaft on gearbox (what bolts to the prop) has no up and down movement / play in it at all.
Input shaft (that engages with clutch) does have up and down movement / play ... approx. 3mm of play, have done a video but not sure how clear it is:



Am still concerned that the input shaft is not sliding into the spigot bearing on back of engine as with the adaptor plate the shaft isn`t long enough to reach it, allowing the shaft to move about where it wants.
So am guessing the bearings have failed on the input shaft, so now need to start searching for a replacement gearbox.

[limitedblack]

That certainly won't help if the spigot bearing doesn't reach.

Is the prop a two piece with floating centre? Only those MT 75 boxes don't work if linked straight to a live axle, due to them not having end float movement like a type 9

[Leeday]

That certainly won't help if the spigot bearing doesn't reach.

Is the prop a two piece with floating centre? Only those MT 75 boxes don't work if linked straight to a live axle, due to them not having end float movement like a type 9

Hiya,

Using a mk5 2.5 diesel 2 piece prop with centre bearing, has the slider in the middle of the prop.

[limitedblack]

At least that bits ok then.

[karl]

great thread took me ages to read

tim is a very talented man and always their

[limitedblack]

Great bloke, even brings his own BBQ

[Leeday]

Well have took some measurements:






Seems the splines on gearbox connect with the clutch pressure plate ok, I think the end of the gearbox shaft doesn`t quite reach the spigot bearing in the back of the engine though, starter motor engages with ring gear ok, so looks like I need to modify the clutch release arm so as to move the release bearing further forward.

These are the measurements I done when I done the transplant (page 6 of this thread) and the input shaft protrudes 6mm from front face of gearbox, the gearbox face bolts to the adaptor plate (between engine and box), adapter plate is 10mm thick so there is no way the input shaft will reach the spigot bearing as its already 4mm short of getting past the adaptor plate.

[karl]

so your saying it needs to be another 6mm thinner for the input shaft to sit in the spigot bearing

a dont quiet understand what you saying

[Leeday]

Normally you would bolt the MT75 gearbox direct to the back of your engine (2.0 pinto, 2.5 diesel, etc) and the input shaft would (with a 6mm protrusion) slide into the spigot bearing on the back of the engine. As I have put a 10mm thick adaptor plate between the Essex V6 and the MT75 gearbox the 6mm protrusion of the input shaft is not long enough to go through the adapter plate and into the spigot bearing on the back of the engine, therefore with this conversion the input shaft on the gearbox needs to be longer and protrude further out of the gearbox by at least an extra 10mm making the protrusion from the face of the gearbox at least 16mm, as there is a void space behind the spigot bearing into the engine the input shaft can be anything upto a 40mm protrusion from the face of the gearbox.

[Luke]

does the input shaft definatly not go into the spigot bearing

can you fill it with grease and fit and unfit the gearbox - just to see for sure so if the grease is untouched then it doesnt but if there is grease on the input shaft then it must touch

you could even remove the clutch for the test

[Leeday]

does the input shaft definatly not go into the spigot bearing

can you fill it with grease and fit and unfit the gearbox - just to see for sure so if the grease is untouched then it doesnt but if there is grease on the input shaft then it must touch

you could even remove the clutch for the test

Hey Luke

Do you have some images of me bench pressing my gearbox up and down whilst I`m laying on my back

Will do the test tomorrow and let you know the outcome

[dieselhead123]

Normally you would bolt the MT75 gearbox direct to the back of your engine (2.0 pinto, 2.5 diesel, etc) and the input shaft would (with a 6mm protrusion) slide into the spigot bearing on the back of the engine. As I have put a 10mm thick adaptor plate between the Essex V6 and the MT75 gearbox the 6mm protrusion of the input shaft is not long enough to go through the adapter plate and into the spigot bearing on the back of the engine, therefore with this conversion the input shaft on the gearbox needs to be longer and protrude further out of the gearbox by at least an extra 10mm making the protrusion from the face of the gearbox at least 16mm, as there is a void space behind the spigot bearing into the engine the input shaft can be anything upto a 40mm protrusion from the face of the gearbox.

HI Lee, the Pinto/Mt75 combination uses a 10mm thick adapter plate, both Di and Pinto Mt75's use the same input shaft. I will dig out our drawings later today and post up the info. All the Mt75's we have here, including a Mk7 one, seam to have at least 3mm sideways play in the input shaft, all came from running vehicles, I had not driven all of them though.
How deep in the crankshaft is the front face of the spigot bearing? I can measure the one I have here and let you know.

TIM

[Leeday]

Normally you would bolt the MT75 gearbox direct to the back of your engine (2.0 pinto, 2.5 diesel, etc) and the input shaft would (with a 6mm protrusion) slide into the spigot bearing on the back of the engine. As I have put a 10mm thick adaptor plate between the Essex V6 and the MT75 gearbox the 6mm protrusion of the input shaft is not long enough to go through the adapter plate and into the spigot bearing on the back of the engine, therefore with this conversion the input shaft on the gearbox needs to be longer and protrude further out of the gearbox by at least an extra 10mm making the protrusion from the face of the gearbox at least 16mm, as there is a void space behind the spigot bearing into the engine the input shaft can be anything upto a 40mm protrusion from the face of the gearbox.

HI Lee, the Pinto/Mt75 combination uses a 10mm thick adapter plate, both Di and Pinto Mt75's use the same input shaft. I will dig out our drawings later today and post up the info. All the Mt75's we have here, including a Mk7 one, seam to have at least 3mm sideways play in the input shaft, all came from running vehicles, I had not driven all of them though.
How deep in the crankshaft is the front face of the spigot bearing? I can measure the one I have here and let you know.

TIM

Hi Tim,

Sorry, I stand corrected, I am thinking of the "Old Skool" days when you had a 1mm sandwich plate between the engine and box
Have been unable to do anything today as had to go to work, van off the road, my missus has the Mondeo Estate as she is visiting family in Northamptonshire, so had to go to work in the Motorhome
Will try and measure the spigot bearing and re-fit gearbox to see if input shaft is reaching the spigot bearing tomorrow.

[Leeday]

Ok, so been rolling around under the van and firstly would like to apologise to everyone, especially Tim .... the input shaft DOES slide into the spigot bearing by about 15mm after lifting the box back in with blue hylomar on the input shaft (thanks madbri) and seeing the blue stuff on the bearing I re-measured and it is all become clear, the spigot bearing / housing is further forward to the gearbox than I thought and so my original measurements were taken from an incorrect point, so again apologies for the incorrect info I have been supplying.
So as the input shaft has no excessive up/down movement and the output shaft has no excessive up/down movement is it safe to assume that a bearing on another shaft inside the box has failed and causing the over-bearing noise when driving? as mentioned before the gear oil that come out has no bits or shards of metal in it and is as clean as when I put it in.
Flywheel and clutch all tight and fitted with nothing rattling around in it, prop centre bearing is ok and prop alignment is true, back axle is fine with no movement on where the prop bolts on.
So as I have no idea about stripping the gearbox is a replacement the only option.

Many thanks for all your patience.