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Help With Gearbox Swap In Adelaide

RubyRS4

By RubyRS4,
in Four Door Family & Wagoneers

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RubyRS4 Grand Master

RubyRS4

Posted
Posted

Hiya all,

I'll be picking up a manual AWD box for the stagea this week sometime, together with all the additional bits I need for the swap. Just wondering if anyone has done this kind of swap before, and if they would have any suitable premises for such work. My house is under construction for a house extension, so there is no room for me to do it there ... and I think Tracy has banned me from doing such work at home :D

I'm no stranger to working on cars, but wouldn't mind a hand for ease of work and a speedy job ... plus its always best ofr another set of eyes to be going over the job. Not too keen on paying a workshop to do it ... but not keen on doing it alone ... so aiming for somewhere in the middle!

There's a carton of beer in it for any assistance. I'm keen to start (and finish) the swap not this weekend, but the next. 33 is sold, so the Stag is my daily.

;)

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kidafa Veteran

kidafa

Posted
Posted

perhaps get it touch with luke? He's got access to a hoist I believe and knows his shit.... Dono what the going rate for hoist use is but if I was doing a trans swap id WANT a hoist and perhaps a trans stand/lifter.

Also maybe have a chat to mike about it as he's doing his shortly and seems to have it all sorted.

KiwiRS4T Grand Master

KiwiRS4T

Posted
Posted

I presume you have read the "how to" in the DIY section by Trukboy. Its pretty spot on. Being old and decrepit I paid my workshop to do it (about $700 labour $2000 allup). The main problem is that both the auto and the manual are really heavy so if you dont have a hoist and a transmission cradle you will need to make sure you have four good reasonably high stands and a good floor jack. I would say to be safe you want three people to get the box in and out. i got an R33GTR box and was able to retain the original cross member and drive shaft. The only tricky bit I noticed was the comprehensive piping for the clutch including the damper ciruit. I ended up using another clutch pedal setup without the booster as it was a rushed job (my mechanic very kindly did the job on a Sunday night because I was booked for a track day at the new Hampton Downs circuit on the Monday) so with a heavy duty clutch it has quite a heavy pedal - not a problem when driving -only at the lights. Also the handbrake mounting point has to be welded in (I think Trukboy was kidding about the pop rivets) but you don't need the handbrake to go to work!

RubyRS4 Grand Master

RubyRS4

Posted
  • Author
Posted
perhaps get it touch with luke? He's got access to a hoist I believe and knows his shit.... Dono what the going rate for hoist use is but if I was doing a trans swap id WANT a hoist and perhaps a trans stand/lifter.

Also maybe have a chat to mike about it as he's doing his shortly and seems to have it all sorted.

Might have to get in touch with both of them then ... work something out. Done gearbox swaps many times, but I wanna do it once and do it right with the Stag. At least I'm finally sticking to my plans to go manual by the end of the year :P

Hmm, just realised, I still do not have a flywheel. Better shop for one right now!

Duncan Grand Master

Duncan

Posted
Posted

if you are going to remember anything....remember there is a brass spigot bearing to put into the rear of the crank for a manual!

the box itself is easy

the clutch line is easy if you use a straight braided one

the pedal and boost assembly is the PITA

good luck!

darrinspencer Grand Master

darrinspencer

Posted
Posted

Post up a full list of parts you already have and see if I can help with anything missing etc.

All RB flywheels are the same.

What handbrake?

What clutch pedal set up?

What brake pedal?

Etc

Thought about changing the rear main crank seal will the box is out. Can also go the front gearbox seal I think

RubyRS4 Grand Master

RubyRS4

Posted
  • Author
Posted

I'm getting the gearbox and other conversion bits from Dan who is parting out BITSUS's old 260.

Already got pedal box and clutch lines, master and slave cylinder etc, clutch kit, handbrake organised (most of which coming out of BITSUS's old 260).

Currently sourcing spigot bearing, flywheel, and centre console.

Picking up a majority of the parts tonight.

:)

darrinspencer Grand Master

darrinspencer

Posted
Posted

It is the minor little things that will hold you up

Flywheel bolts, they are different to the auto flex plate

Need a few longer bolts between the gearbox and engine.

If using the Stagea handbrake lever, good as they are different to the skyline ones. Remove the mounting bracket that is welded to the 260RS shell and either reweld or put thru 4 bolts and larger washers thru tailshaft tunnel.

If you are going to use the 206Rs clutch booster you will need to cut a larger hole thru firewall and recess the booster. Not a easy task. I used a r34 GTT master without booster, same as a RS4 S but you will need a different bracket and possibily pedal.

Don't forget you will need to join 2 wires behind the RH head light otherwise the car will not start.

If you do get a center console the g sensor and other relays get in the way of cup holders.

You can fit the handbrake, clutch master and pedals and do the wiring mod prior to go to the shop for the gearbox change. Saves time and keeps car mobile.

Gearbox weight approx 90kgs!! It sucks even with a hoist and gearbox lifter.

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