Fitting a Duratorq Diesel in a Mk5 Transit

[V184]

Are the sumps different on 2.0 and 2.4 then ??

One would imagine its baffled differently as ones transverse & the others inline,

[bambi mk 1]

You would need two drivers one to steer it and one in the back to change gear

[/quote]





I cant see the gearstick would be that far out on the original mk6 box

Using the 2 litre would you not also have to modify the sump ?[/quote]
If 6inches is not far then its not far Don't be baffled with the sump as there are no baffles in the sump

[V184]

You would need two drivers one to steer it and one in the back to change gear

I cant see the gearstick would be that far out on the original mk6 box

Using the 2 litre would you not also have to modify the sump ?[/quote]
If 6inches is not far then its not far Don't be baffled with the sump as there are no baffles in the sump [/quote]

Is the mk5 gearstick not angled "back" ? Regarding the sump i fitted a Mondeo Zetec in a kitcar & had to have a different sump/oil pickup due to surge, there again if its having a mttdi mod there wont be much chance of surge

[Mad machinist]

You would need two drivers one to steer it and one in the back to change gear

there again if its having a mttdi mod there wont be much chance of surge

Oh V you are a wag

[bambi mk 1]

Best get the gear stick on your head and put your brain into gear this thread is about fitting a Duratorq diesel into a mk 5 not a Zetec into a skit car

[ffsagain]

You would need two drivers one to steer it and one in the back to change gear

I cant see the gearstick would be that far out on the original mk6 box

Using the 2 litre would you not also have to modify the sump ?

If 6inches is not far then its not far Don't be baffled with the sump as there are no baffles in the sump [/quote]

Is the mk5 gearstick not angled "back" ? Regarding the sump i fitted a Mondeo Zetec in a kitcar & had to have a different sump/oil pickup due to surge, there again if its having a mttdi mod there wont be much chance of surge [/quote]

Do you not rate the mtdi conversion then ?? If so why not ??

[oldyellar]

It's only mk1 above floor level, all the rest is from the original van, doesn't really look right imo

Yes, however Geoff Hunt built a mk1 with a125ps 2.4 duratorque engine and box in it

[V184]

It's only mk1 above floor level, all the rest is from the original van, doesn't really look right imo

Yes, however Geoff Hunt built a mk1 with a125ps 2.4 duratorque engine and box in it

Thats the one i was thinking of ^^^, nice conversion

[dieselhead123]

A few points about using the 2.4 Duratorq gearbox in the Mk3/4/5

The gear lever would end up approximately 9 inches further back compared to the 2.5 Di Mt75 so might interfere with the hand brake mechanism, or at least the reinforcement beneath the floor.

A replacement/modified gearbox cross member would be required.

A replacement/modified propshaft would be required.

The 2.4 Duratorq Mt75 gearbox features hydraulic clutch actuation, this would require modification of the clutch pedal and installation of a clutch master cylinder and associated lines.

The 2.4 Duratorq Mt75 gearbox has an electronic speed sensor and no provision to fit a speedo cable. To use the electronic speedo output of the 2.4 Mt75 you would not only need to install the Mk6 instrument cluster but also the Mk6 ECU and a good amount of the Mk6 wiring.

Far simpler and easier for the installer to retain the factory 2.5 Di Mt75


We are now working on the additional parts to complete this conversion kit, here we have the spacer that is to be installed below the clutch lever 'pivot ball' inside the bell housing;


The 'pivot ball', (lower image), should be removed from the gearbox bell housing with the aid of a suitable drift, this should then be pressed into the spacer, (upper image) and re-fitted to the inside of the gearbox bell housing.

TIM

[ffsagain]

Looking good tim, any luck with a spigot bearing yet

[dieselhead123]

Looking good tim, any luck with a spigot bearing yet

The spigot bearing we will be using is the same part that we supply with the RV8 conversion.
A batch of spigot bearing 'housings' are being produced and should be available by the end of the week. The spigot bearing 'housing' will press into the end of the crankshaft, (if using a 2.4 engine you will need to remove the existing bearing). The spigot bearing will be supplied pre-assembled in the 'housing'.

TIM

[dieselhead123]

Just got the Spigot Bearing Adapters back this morning;


Here we see the Spigot Bearing installed in the Adapter;


The Adapter is fitted into the end of the Crankshaft;

and then knocked fully 'home', a suitably sized socket will suffice for this purpose.

The complete kit is now ready, it includes the adapter plate, a clutch arm pivot spacer and a pre assembled spigot bearing housing. The price to forum members will be just £185, national/international postage will be provided at cost.

TIM

[Mad machinist]

Well i go on holiday for just a few days and ive been usurped, lol.

[dieselhead123]

Well i go on holiday for just a few days and ive been usurped, lol.

Get your feet out of that pool and get back here in the cold

TIM

[Mad machinist]

Thinking of home constantly, did that sound believable Timbo, Alan