This thread is about the development and fitting of an adapter plate between the Mk5 Di Mt75 gearbox and the Mk6 Duratorq engine. Once the adapter plate has been finalised it is hoped that the member will add to this thread with information regarding fitting of the engine into the van.
The first stage of the process was to 'overlay' the CAD drawings form the two engines, after a few measurements were taken, it was decided to use a 10mm thick steel plate, a 'first cut' was produced.
Here we see the plate bolted to the rear of a 2.0 Duratorq engine;
You can clearly see the familiar shape of the Di bell housing in the plate.
Many modern engines, the Duratorq included, feature cast alloy sump pans that accept bell housing fixings, with this in mind our Di bell housing plates have been altered to accommodate this, all new plates will feature a 'complete ring' fully enclosing the lower part of the bell housing avoiding the need to install an additional steel plate below engine block level.
With this conversion we have decided to use the existing Duratorq starter motor, the large 'hole' that can be seen in the plate is needed as the Duratorq starter 'overhangs' the gearbox;
With the plate fitted to a Di gearbox you can see that a section of the casing will need to be removed to accommodate the starter;
As this is intended to be used with both the 2.0 and the 2,4 Duratorq engines, we next looked at the flywheels. The 2.0 and 2.4 flywheels are interchangeable as regards fitting to the crankshaft but the 2.4 unit is 'thicker' than the 2.0. The increased thickness of the 2.4 flywheel places the clutch further inside the gearbox bell housing and was deemed more suitable for this conversion. In both cases the flywheels we checked were factory Ford 'solid' units.
If you are using the 2.0 engine you will still need to use a 2.4 flywheel.
More later,
TIM
Fitted a clutch to said van last week and still flying.
