My Tuned AE86 project

[thanhngo]

Goal: Build a versatile car that you can have fun/learn in everyday and capable to be used on circuits and sprints etc.

I purchased this shell, it was an uncompleted project with no engine and a T50 gearbox. Nothing exciting here, just your standard SR5 equipment onboard.


I had a spare EFI fuel tank in the backyard which was rusted;


Used POR15 fuel tank repair kit on it.



This stuff was great so I painted coated the outside to protect it from roadchips and prevent future rusting.

[banpei]

That's a big difference!
Where are you from btw?

[thanhngo]

As I'll be fitting a 20V I thought a 6-speed transmission would complement it nicely.

With a few possibilities, but I ended up getting a S15 az6 gearbox.
T50: 3.587 2.022 1.384 1 .861
AZ6: 3.626 2.2 1.541 1.213 1 .767

It has very simliar ratios to a TRD-851 gearset but made more streetable as its got a first gear and over drive for fuel saving

Some pics to compare the AZ6 vs a T50.

[thanhngo]

Problem #1 was the cost But I managed to convince myself to buy it.

Problem #2: its 45 kilos!!!

Problem #3 is the S15 does not have a speedo drive. On the S15, speed pulses are taken from the ABS sensor in the rear diff. One of the reasons why I brought the S15 box was I suspect it is capable of holding a Speedo drive of some sort.



As you can see there is a casting for the speedo hosing to fit and I assumed the it would align to the output shaft for a worm drive of some sort. I opened the rear housing but there is no worm drive or any grooves or dimples to hold one.

After further research, the J160 from (is200) seems to be the only AZ6 box that has a speedo drive gear - (I don't count the S2000 as that box looks vastly different). As the J160 speedo housing is interchangable with the W5* box, I will try use a W5* worm drive/housing to get a speedo mechanical drive.

[Jan Pedersen]

This is interesting with the AZ6 box! I'm looking forward to seeing how you get it swapped in BTW Dan aka Oldeskewltoy is trying to make a kit to do the T50->AZ6 swap you might want to check it out :wink:

[banpei]

See also here:
http://www.aeu86.org/viewtopic/t50-to-az...ues/t/4283

And here for pre-orders:
http://www.aeu86.org/viewtopic/az6-swap-...ble/t/4798

[thanhngo]

There's been 2 people I read of who have successfully installed a AZ6 so I'm not breaking new ground...Just documenting the pain Dan's kit looks like a nice option - I'll tackle the "mating" problem bit later when I do more proper measurements.

Visited my local wrecking yard for my daily exercise today...

measured the Diameter of the output shaft where the Worm drive is suppose to be in the S15 box and its ~27mm.

So im looking at finding a worm drive that can fit this.
I measured a W5* auto box and it was ~29mm so thats bit too big. I assume the T50 is ~25mm based on the output spline.

I've ordered a S14 worm drive (wild guess because the boxes look very similar) so I will have that tommrow to test - and hopefully fit.

[thanhngo]

Update on Worm Drive for Speedo:

S14 worm drive is too small ID so wasted some money there.

Now I will try my luck with a J160 (IS200 AZ6) worm drive as its the only AZ6 I know of that runs a worm drive near the output shaft. Will see in about 2 weeks - but it looks like I may need to get a spacer machined & welded to my output shaft as a last resort.

Mating the AZ6 to the 4A block.
For individual reasons, I will probably try get this one to fit myself. Here are some of the key measurements I took;

(T50 vs Az6)
Face-shaft tip: 5.5mm vs 17.8mm
tip-spline start: 23.7mm vs 33.4.mm

Basically the AZ6 box runs a pilot bearing on the flywheel as opposed to the crank like the T50. Thus it has a much longer tip and sits much deeper inside the face of the bellhousing.

From the spline back, the T50 and Az6 are very similiar in lengths etc. The thrust release bearing from fit on each others shafts

Option 1. Adapter mating plate
There is a -22mm difference that needs to compensated for to get the clutch system to work like the T50. If you add an adapter plate to this, it would be at least -30+. So to achieve this with a Adapter plate, I would have to mill the bellhousing face down, use flywheel spacer, possible new bolt flanges. I figured this is a the more messy option.

Option 2. Cut and mate/weld both bellhousings. As crude as it sounds, this seems to be the most logical as I will need to spend time making sure I cut/weld at the most ideal points. So this is the option I will pursue.

Its a writeup of someone doing something simliar using a I200 6speed (az6 - J160).

I found this link:
http://www.rsmotorsport.com.au/forums/vi...57208cc182

Really helped and gave me some ideas.

...lots of babble but this needs to be carefully planned as I probably only have 1 shot at this.

Got a new a pilot bearing (15 IDx28 OD x7 WID). The Input shaft will need to be shaved at the tip, 1mm and shortened 9.7mm to work like a T50 would.

Next step is to locate cutting/matting positions.

[thanhngo]

Haven't really being doing much but for those interested in the gearbox, I think i've found the solution.

Problem:

S15 gearbox doesn't have a speedo - it runs from abs sensor/signal converter. So anyone using a S15 box as a transmission without the diff needs to find an alternative speedo.

Luckily the IS200 gearbox has a speedo worm gear / and speedo drive. This speedo drive interchanges with the W5* boxes so you can convert IS200 electronic speedo to cable driven this way. So back to the problem the S15 shaft doesn't run any worm drive and hence no speedo capability. The worm drive from a W5* is too big ID and does fit. So heres my attempt to adapt a IS200 worm drive onto the S15 gearbox.

Parts were purchased from lexus dealership. Try remove the 'T' and ask your local toyota dealership...it may even be cheaper!!! dunno.

Part# T33481-22030, Worm gear for IS200 6-speed, cost $60


Part# T90467-25001, Clip retainer for IS200 6-speed cost $3.50



Now the gear fits perfectly over the shaft as in above picture. All I think you need to do is drill 2 holes so the clip can clamp onto and you have a worm gear on the output shaft of your S15 gearbox (and possibly work on MX5/RX.


I haven't progressed further than that but im sure it will line up to the casting that exist on the box. That will determine where you drill the two holes (though im guess central location is best) but will need to do measurements.


P.S. I have not tried this on my own box so I do not know if it will work 100%. But it take me few months before I even look at it so enjoy the info.

[thanhngo]

Been bludging around for a while...playing with ideas of different engines (SR16ve, f20c) but decided on:





Going to use SP-tec relocation in the first stage (I have aftermarket ECU but thats going to take bit longer to setup)