Gearbox case modification
Turbo Mini Forums

Got a bare case here at the moment ready for the straight cut set
What modifications can I do ? Stress relief?

Windage tray, stress relieve the centre web

IMO make it very clean that's all

Is there any photos on here that show the strees relieve centre that you know off ?

Have a look at my build page mate, I am sure there is some on there,

I have started posting on Instagram also my name on there is turbomk1golf

Nothing is impossible it just costs more and takes longer.

Here you go mate,


http://www.turbominis.co.uk/forums/index.p...=294168&fr=1475

I have started posting on Instagram also my name on there is turbomk1golf

Nothing is impossible it just costs more and takes longer.

Inspect all the bearing bores very carefully. I assume you have the three-hole mainshaft bearing retainer, not the 4-hole version? If the 4-hole, you might want to go and look for another casing.

Check each and every fastener hole very carefully to make sure the threads are good (incl sump plug) and heli-coil any that are suspect. I also reccomend winding a bottoming tap down all the diff output ones, so you can maximise your thread engagement, if not now, then a few years from now when you accidentally manage to strip out the first 3/8" of thread lol...

I also like to mount a few extra magnets into the sump just for good measure.

Thanks for the info yes it's the 3 bolt version.herd they crack don't know how common it is but never experience personal
All thread are good with no helicoils present. I will be have a widget tray fitted to already got a few extra magnets so happy day.

Thanks you
Did you use a die grinder ? Or something more fancy ?

Also any recommendation on someone to modify the case for a lsd ?and have the case Cleaned Wasn't quite happy with my local shop

Edited by kezzboycat on 27th Dec, 2015.

Well this is something I have spent all day yesterday doing! I stripped 5 gearboxes in the end and still not find one I was happy with! Really have s good look over every part of the case! As what's the point if it's not up to the job...

I have learned the hard way in the past if I say "that will do!" It always comes back to bite me in the ass and costs more!!

I have started posting on Instagram also my name on there is turbomk1golf

Nothing is impossible it just costs more and takes longer.

What types of problems have you come across simon?

Just not happy with the casting in places, or threads gone.

Lots of things really.

I have started posting on Instagram also my name on there is turbomk1golf

Nothing is impossible it just costs more and takes longer.

have a good look at the brain plug threads.

Yes joe I have what was a spot on one, washed it and got it ready, to start then pulled the plug out, and it had a the threads with it! Think the last bloke put it in side ways.

I have started posting on Instagram also my name on there is turbomk1golf

Nothing is impossible it just costs more and takes longer.

LOL!

always the good old helicoil though,

I want to stay away from them mate if I can.

I have started posting on Instagram also my name on there is turbomk1golf

Nothing is impossible it just costs more and takes longer.

Whats ya problem with helicoils Simon? I helicoil mine just for peace of mind, my sump plug is helicoiled too

I seriously doubt it!

I always seen them as a fix.

So what you do all yours? Or just your sump plug?

I have started posting on Instagram also my name on there is turbomk1golf

Nothing is impossible it just costs more and takes longer.

Any that have bolts going in and out of them, I dont bother with the ones that studs go into apart from the two that I use for lower tie bars

I seriously doubt it!

If you have the gearbox stripped, helicoils are super-easy to do, and honestly if you've never used one, a stripped trans case is about as easy as they get to practice on. Also, they could be construed as a fix if the thread is damaged, but I've seen occasions when helicoils (or more preferably time-serts) are used in high-stress, high maintenance, or damp environments in brand-new applications. A properly installed insert (in alloy) is almost always stronger in tensile loading (and more resistant to over-torque abuse) than a simple threaded hole.

I personally find the sump plug can be a bit of hit-and-miss to helicoil, as it is a sealing area; get any slight mis-alignment to the tapping phase, and you will have problems.
That said, if you set it on a mil, then drill, tap, and spot-face it, this will be assured of being a good solid seal as the face is perfectly normal to the thread axis.

Edited by turbodave16v on 29th Dec, 2015.

like turbo Dave says if done correctly you should be miles ahead of what was there from factory

come on guys steel threads vs 50 year old threads in aluminum casting i know what id prefer

i used the "keensert" brand
being a solid insert when you thread it in to insure no leaks use some high temp oil safe sealant install it just proud of the casting so the copper washer pulls up on the insert
its not let me down and i dont stress about jacking the threads up if im in a hurry doing the oil change

i fell it's superior to the helicoil or spring types you dont need special tools altho a mill would make it real nice just to get is square altho it you take your time you'll get is close just leave the insert proud a litle so the copper washer seals good

i did mine free hand just drilled it to the tap size, taped it, clean the tap fluid from the threads with acetone and comp air, brush some sealer on the insert, screw in by hand stop short of the casting, punch the locks down and your done

all you need is the tap and tap size drill and some sealer

http://www.thorintl.com/Keenserts-Keyserts...g-Inserts.shtml

Ive only used cheap ebay helicoil kits, but they have been fine, although I did do the oil driain using a pillar drill to get it all straight, fuck doing it on the car,

I've never had problem with helicoils before even on head bolts not on a series though
I must be lucky then as my case had no helicoils or threads damaged well for now anyway

Helicoils are not just for repairs; I believe they sometimes get factory fitted for some applications.
If the box is apart, I always fit one in the drain plug now whether it needs it or not.