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Go Back   Madabout Kitcars Forum > Mad Build Area > Marlin 5exi builds

Marlin 5exi builds Calling all you sexi builders....sorry 5exi builders, show us your progress.

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  #1  
Old 23rd July 2008, 08:00
eaa53's Avatar
eaa53 eaa53 is offline
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Default MGF Gear Change

For those of you interested in the MGF Gear Change Installation I have put together some detail and pictures to assist you planning.

It has already been done by others so more detail and information may follow.


List of item you will need
Gear stick and in-cab mechanism
Two gear shift cables with retaining clips from g/b end
Three brackets off the gearbox (retain the mounting bolts)

Removal from MG
The removal of the required components is not an easy task if the rear subframe and engine are still fitted. There are 8off 8mm studs holding the weather proofing plate onto the rear bulkhead. If these bolts shear off that's good, if they unscrew its time consuming as one is directly behind the sub frame. If they round off its a real pain as they will need to be chiselled or cut off in some way with limited access.

Take care separating the socket/ball joints from the gearbox end, if you prise off using the larger outer metal ring there is a possibility of breaking the rubber webbing and needing to buying new ones. Use an open ended spanner and leaver directly on the smaller socket carrier.

The shaft bracket has a pin holding in position hidden under a clip, there is just room to drive it out the other side to pull the bracket off the shaft, just.

Retain the studs holding the brackets onto the G/B casing as these holes are not used on the 200 installation so you will need the studs to hold your brackets onto the G/B. Note the different stud lengths as well just to add to the rebuild puzzle, they will need to be used in the same holes to avoid bottoming out.

Prepare for installation

Check the cables and repair any chaffing to the cable sheath, the cables are £90 new but are well built so should continue to operate if they are not broken.

No changes are required to the gearbox end, just reassemble as removed.

The in cab mechanism needs some serious carving to get it into the tunnel.
The pictures indicate that you cut off:-
the counter weight (remove as much of the rod as possible)
the side wings,
the front leg,
the rear leg, retain enough to mount the cables and cable retaining plate.

Weld or bolt on a new rear mounting to reach the existing chassis rear mounting, drill the front to match the chassis front mounting bracket.

Installation
The installation of the gear box end and the cables is straight forward.
The short cable goes under the gear box and will connect to the left-right actuator ball mounted nearest to the drivers leg. Could be an interesting gear shift if you change them round!

There is room to install all the pipes and cables, I am not installing the heater pipes through the tunnel but there is room in the top of the tunnel arch, i.e. above the gear change mechanism.
I have installed the steel petrol and the hydraulic clutch pipes in this area in the pictures.

Remember each line, pipe or cable will need to be clipped and protected throughout its length in the tunnel for long term reliability.

In the picture's you will notice:-
1) it all needs to be cleaned up and painted for final installation
2) The cable retaining plate is not fitted correctly, it should circle the cable end not as shown fitted to the top of the cables.

I hope this detail helps you make a better job of the modifications and save you time, cost and effort during your changes.

Sorry about the quality of some of the pictures the camera is due for replacement but never did like taking close up pictures.


Before all the changes
http://img.auctiva.com/imgdata/7/9/7...55201593_o.jpg



The gear box brackets
http://img.auctiva.com/imgdata/7/9/7...55201600_o.jpg


Side wings removed
http://img.auctiva.com/imgdata/7/9/7...55201610_o.jpg


http://img.auctiva.com/imgdata/7/9/7...55201607_o.jpg


counter weight and side wings removed
http://img.auctiva.com/imgdata/7/9/7...55201610_o.jpg


Gear box end assembled
http://img.auctiva.com/imgdata/7/9/7...45836426_o.jpg



Rear mounting changes and general layout
http://img.auctiva.com/imgdata/7/9/7...54479419_o.jpg



side view of general set up
http://img.auctiva.com/imgdata/7/9/7...54479424_o.jpg



General arrangement from the top
http://img.auctiva.com/imgdata/7/9/7...54479413_o.jpg



General arrangement from the drivers side
http://img.auctiva.com/imgdata/7/9/7...54479436_o.jpg



General arrangement from behind
http://img.auctiva.com/imgdata/7/9/7...54479442_o.jpg



Tunnel enclosing everything
http://img.auctiva.com/imgdata/7/9/7...54479446_o.jpg



Tunnel in place with steel pipes laid in
http://img.auctiva.com/imgdata/7/9/7...54479442_o.jpg




Regards

eaa53
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  #2  
Old 28th July 2008, 14:07
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limpabit limpabit is offline
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Default

Good post this john.

Makes a good gear selection as well with the PG1 box.
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