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BFH, take two.....


otisdog

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Starting a new thread, so as not to get lost in the sniping of the " does a 5 speed add value thread".

When a 235//5 was ordered as a factory option, how was the tunnel modification handled....with a BFH, as per the blue book? And does the 5 speed overdrive need the same amount of whacking as the dogleg?  How far do you have to 'adjust' the tin to make it work?

Does anybody out there have a 2002 with a factory 235/5?

Edited by otisdog
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The tunnel whacking is really for slave cylinder clearance, not for the trans housing itself. The 235 uses the same slave setup as the 4 speed so no whacking was ever necessary from the factory. The 245 has the slave upstairs and it needs more room.

I think the whacking is overstated. A piece of wood the size of a deck of cards and a bottle jack will get you the clearance you need in a few minutes without ruining the car or affecting the pedals. Take a minute and bolt the 245 up with 2 bolts and no clutch assembly and mark the tunnel up so you don't overachieve while whacking. You can diddle the rear trans mount and shaft alignment while you're in there.

Then whack and final assemble.

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Blue manual states the following , which is why I asked how much needs to be moved...

 

" 23 00 005 - In order to prevent the bracket from knocking against the gearbox tunnel the tunnel should be refinished on the right".

 

 

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Here in Germany we have a couple of shops that machine the 4 speed cases and fabricate a sandwich plate so the e21 5 speed (overdrive and doglegs and M20) can be fitted into that front case.

Edited by uai
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5 hours ago, uai said:

Here in Germany we have a couple of shops that machine the 4 speed cases and fabricate a sandwich plate so the e21 5 speed (overdrive and doglegs and M20) can be fitted into that front case.

 

Uli,

 

What? You can fit the entire 5-speed into the 4-speed housing, without the extra 4" housing extension?

 

That's very cool!

 

Best regards,

 

Steve

 

1976 2002 Polaris, 2742541 (original owner)

1973 2002tii Inka, 2762757 (not-the-original owner)

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5 hours ago, otisdog said:

Blue manual states the following , which is why I asked how much needs to be moved...

 

" 23 00 005 - In order to prevent the bracket from knocking against the gearbox tunnel the tunnel should be refinished on the right".

 

 

 

That's pretty interesting! Could they, possibly, be suggesting that you must remove the old supports for the 4-speed rear crossmember? I've never seen this text, or ignored it because I didn't understand it... ?

 

Regards,

 

Steve

 

1976 2002 Polaris, 2742541 (original owner)

1973 2002tii Inka, 2762757 (not-the-original owner)

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22 minutes ago, Conserv said:

 

That's pretty interesting! Could they, possibly, be suggesting that you must remove the old supports for the 4-speed rear crossmember?

 

 

I think they're saying that you have to REMOVE the 4 speed brackets and not just ADD the 5 speed brackets because otherwise the 235 case will hit the RH 4 speed bracket.

I think.

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7 minutes ago, andyleonard said:

 

I think they're saying that you have to REMOVE the 4 speed brackets and not just ADD the 5 speed brackets because otherwise the 235 case will hit the RH 4 speed bracket.

I think.

 

+1

 

That's what I was struggling to say, Andy! ☺️ And "should be refinished" is simply admitting you'll have to throw some paint on there after you cut off the old crossmember brackets....

 

Best regards,

 

Steve

Edited by Conserv

1976 2002 Polaris, 2742541 (original owner)

1973 2002tii Inka, 2762757 (not-the-original owner)

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29 minutes ago, Conserv said:

 

What? You can fit the entire 5-speed into the 4-speed housing, without the extra 4" housing extension.

 

From what I've heard, they're fitting front housings off 4 speeds onto the front of 245s, allowing the use of the original slave cylinder and release bearing setup.

I wasn't aware you had to machine anything or use a sandwich plate???

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Just now, andyleonard said:

 

From what I've heard, they're fitting front housings off 4 speeds onto the front of 245s, allowing the use of the original slave cylinder and release bearing setup.

I wasn't aware you had to machine anything or use a sandwich plate???

If it works, no widening of the tunnel.

 

Long way to walk for a cold beer....

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4 minutes ago, andyleonard said:

 

From what I've heard, they're fitting front housings off 4 speeds onto the front of 245s, allowing the use of the original slave cylinder and release bearing setup.

I wasn't aware you had to machine anything or use a sandwich plate???

 

Got it!  That sounds much more likely!

 

Thanks,

 

Steve

 

1976 2002 Polaris, 2742541 (original owner)

1973 2002tii Inka, 2762757 (not-the-original owner)

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9 hours ago, otisdog said:

Starting a new thread, so as not to get lost in the sniping of the " does a 5 speed add value thread".

When a 235//5 was ordered as a factory option, how was the tunnel modification handled....with a BFH, as per the blue book? And does the 5 speed overdrive need the same amount of whacking as the dogleg?  How far do you have to 'adjust' the tin to make it work?

Does anybody out there have a 2002 with a factory 235/5?

I have a car with factory specified 5speed. AFAIK the 235/5 fits the standard tunnel.

The rear mount brackets are welded in the correct position (not bolted), there is no sign of 4sp position mounts. Therefore I surmise that the body was specific for the 5sp with correct bracketry.

 

However, when I look in the parts book for body shells I see separate part numbers for LHD, RHD, manual sunroof, electric sunroof....but no gearbox choice (if they had a separate part no for the different bracket for the electric roof, why no separate number for the gearbox mount bracket???)

 

 

'59 Morris Minor, '67 Triumph TR4A, '68 Silver Shadow, '72 2002tii, '73 Jaguar E-Type,

'73 2002tii w/Alpina mods , '74 2002turbo, '85 Alfa Spider, '03 Lotus Elise

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1 hour ago, andyleonard said:

 

I think they're saying that you have to REMOVE the 4 speed brackets and not just ADD the 5 speed brackets because otherwise the 235 case will hit the RH 4 speed bracket.

I think.

 

No, R&R'ing the brackets is addressed in a later passage. There is a graphic showing the area of the tunnel that needs to be modified for the 235/5 to fit.

Edited by otisdog
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