Mazda-menders roadsters ,01,02,04

[Mazda Mender]

Chaged a few other things and still not hitting 4th? so it looks like she needs a gearbox change, now this is the Delmar now, do i change/convert her to a manual or replace the Autobox.
Now I do really like her as an Auto, and the auto is very under rated, she was bought as an auto because of the motorway use, and her character is as an auto an anyone that as had the pleasure to try her have always been gob smacked.
So she is staying and auto, i have refurbed the new box, new filter and diaphragm etc, but the auto boxes were never built with a drain plug on the sumps, so mission drain plug is go, so it will be done and ready to fit.
All done ,painted and refitted ready to be man handled into her in the near future...

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[Mazda Mender]

Removed the black mohair hood and frame off my MK 1 over onto ashleighs white one ,so re skinned the beige skin onto a MK 2 frame and fitted it to mine, dig out a new passenger rear caliper as it started to stick? while she as been stood, but it could also be a cable? i have both just in case, so thats on the list as well as the gearbox change which should be happening in a weeks time, i'll be happy to be back in her....

[Mazda Mender]

So after a long day of stripping and cursing trying to get everything to align up correct on the autobox , torque converter and engine on the MK 1 black blur, we came to the point of f*ck it, so she is going to become a manual, so sunday was a day of getting as much together for the conversion, i am only 3 items short, which is not bad, on the plus side there will be a correct guide built on how to do the conversion with the "correct " items needed, i have done the rear crank seal while its all off.
Did not get much of a chance to do many pics but i'll post what i have, my week will now concest of getting everything ready, patch lead for neutral and reverse and prepping everything ready to mash the jigsaw together .
She will be getting a 5 spd MK 2 box, and a 4.1 lsd....

[blackyb]

Nice to see an expert hit the proverbial brick wall, auto to manual and a full write up, means some interesting reading to follow.

[Mazda Mender]

Not a brick wall really , just a really really hot ,day ,lifting a heavy box to align up on your back, and it was just a case of ,had enough, we would of got it in the end , but i always said if the box plays up i'll change her to manual, so it is what it is really.
Any way more pics... and yes before anyone mentions it ,i have got paint on the friction plate of the fly wheel, it will be removed before fitting, i got most prepped ready to fit last night , gearbox to clean and diff tonight and a few more nuts and bolts, they took some cleaning....

[GlennyGills]

Nice attention to detail

Keep up the good work.

[Mazda Mender]

Well its all coming together, slower than i wanted but thats because of the massive amount of pics being taken to do the walk through guide and the fact that it was the hottest weekend so far, it was nice but a killer, lovely at 7am when we started but by the time you get to 8/9pm you are filthy and knackered.

So up date. everything is in or on bar filling the box and diff with oil, peddle boxes. clutch master and bleeding, we did one of the rear calipers also and we need to investigate a fuel leak???? that i had smelt .
My massive thanks to Ally and Daryl, this is not a job to do on your own and even more so with the pics being taken as we go, stopping every five farts to freeze frame.

Any way some selection of pics to nosey at....

[Mazda Mender]

Just an update... you know how jobs expand,,,well i have been getting a waft of fuel so we stripped the rear deck down to investigate ? nothing? but you can clearly see from underneath where fuel as ran making the underseal to melt, but nothing and we tried everything?, but while she is up in the air i am going to re address a couple of small areas with fresh underseal first and do a coolant flush, before she hits the ground for the rest of the conversion, because i would only need to get her back up in the air again ,so may as well sort now, and i'll change the fuel filter also, may as well, i had to put the floor pan back right from where the tyre guy just used a jack any where, which i was annoyed about.

Down pipe bracket to gearbox bracket all bolted up, and the diff, gearbox oil is all in....
I'll update as and when...
M-m

[Mazda Mender]

Sorted some areas that needed attention underneath,with the annual check of undersealing to keep her good on my Mk1 VS II (auto to manual), there is a strange fuel leak that we are trying to find, it does not help that I still have no smell and taste to help sniff it out, so number one son will help find it, but rain stopped play,will dig even deeper tomorrow to sort it...new rear fog lamps on the project 16 and Darys MK1... And prepped the newer alignment bolts for project 16... hopefully we'll finish the conversation this week?did not manage to take all the pics because of the weather, but here is what there is....

[Mazda Mender]

Both Pedal box's in, clutch master in and all back together, found that the ignition plug needed changing( one job leads to another) just need to bleed the clutch up and waiting on the rubber coating for the fuel tank to arrive to apply and then fit.

[Mazda Mender]

She is giving me a fight....came to bleed off the clutch and the master is seized solid , so that as now been removed and pipe disconnected ready for another one to come, then i noticed a piece of the throttle cable sticking up ,then on rubbing it with my thumb and fingers i watched it start to fry even more as it broke from being thin, so another job to the list, i guess she is 30 years old at the end of the day, so waiting on a throttle cable also now, and good that i spotted it now rather it snapping or getting jammed on the road, rubber coating on the newer tank as been applied, and i have cut a oil blocking shaft from an old prop to go in the gearbox for when we remove the prop to do the tank to stop the oil leaking out everywhere, i am not looking forward to it i'll be honest...
Rear brace off,
Zorst off,
Disconnect the rear loom from the sub,
Disconnect the handbrake cables,
Disconnect the brake lines,
Disconnect the suspension,
Disconnect the PPF,
Disconnect the prop,
Support the engine and box,
Disconnect the fuel hoses/lines,
Remove sub/diff,
Remove tank,
swap everything over from the tank,
REfit everything, bleed off, align, tighten up.
Throttle cable,
Bleed clutch,
Coolant system flush,
Next????

Any way, 10 mm spacers fitted,and electric boot popper...
So there is not a lot i can do bar strip the back end ready for the tank really now, i might mark up and remove the alighment bolts, grease them up and put them back.

[Mazda Mender]

So clutch master in and bled off , i have a working clutch, and the faster cable as been replaced....
Alignment bolts and tank next....

[Mazda Mender]

Update time....
So time to swap the tank out as the old one is weeping fuel, which is frustrating because she was stripped down and would of been a far quicker job, any way a good s/hand 1.8 tank was found and i set to work stripping ,sealing ,rubber coating and painting ready for the next roll around on my back with my lad....
The only real bits that gave me a fight was the 12mm head bolts that held the tank in place that had slightly deteriorated, so with a couple of extensions bars and a 3/8's socket gently persuaded to lock on with a lump hammer and a good few hefty whacks , they all came out with the threads looking like they were brand new, so new ones and plenty of copper slip on the way back in.
Coolant system flushed and back flushed and fresh OE coolant added...Engine flush and fresh oil added.
Brakes were all re bled off and hand brake set again, 10mm spacers added, undersealing addressed where needed, test drive gave me no speedo drive, so underneath to check connection, all was fine , turned out it had pulled off the back of the clock while we were working on her.

So thats it she is back on the road again...

[Mazda Mender]

Handbrake lever handle is showing its age . so i de varnished another handle and a OE gear knob, and then thought if i am doing one i may as well do them all, so 3 x wooden brake handle and 2 x OE gear knobs stripped and ready to be re varnished, and found a cracker of a gear knob on the bay of e for £40 delivered...

[Mazda Mender]

deep cleaned a set of wheel nuts and locking nuts then painted them up ready for my lorber rims going on and made up some brackets to fit the thinner cooling fans to my alloy rad, Daryl's and Ashliegh's Mk 1's also at the same time....