My EZ30 build for real boost

[bigBADbenny]

Amazing!
What part of the front diff install went sideways to require pulling the gearset?

[Taj]

Amazing!
What part of the front diff install went sideways to require pulling the gearset?

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So in pulling the front clutch housing off (where the front diff lives between the sundials), you remove the 7-or-so main casing bolts that hold both the case and clutch housing together.

I wasn't careful enough in trying to get the clutch housing only to separate (#2 in pic), and the sealant at the main case came away first (#1 in pic). And when I went to seal the main case back up and bolt it back down, something was misaligned and the input/output shafts did not spin. I suspect it was a shift rod misaligned due to it coming apart while laid down horizontal, causing the fork to position the shift collar oddly over a gear - on tear-down I found one of the shift collars was sort of in 'limbo' between the synchro teeth and gear teeth making the clattering noise i'd heard.

Moral of the story, just lay the box horizontally and get it started with some prybars at #2 only.

Maybe I'll write a little bit of an instructional for the diff job - because I did have to piece together some info from multiple sources before I had much of a "walkthrough" instruction set

[bigBADbenny]

Thanks for that writeup!
I remember feeling a little overwhelmed just reading the FSM procedure for the front diff job…

[Taj]

I got into the old motor that let go today. I stole the intake cams like I'd mentioned earlier to get that combo of the facelift intake cam and pre-facelift exhaust cam.

Here are some pics of the finds, haha!
I found it hilarious I was able to remove the piston & small end, and the rest of the rod thru the bore and block window with the rest of the short-block still together.
Only one bent valve in the head, I could probably even re-use the spark plug

It hadn't spun that rod bearing, and it actually looked in pretty good condition. Just stress making high power for a skinny rod, for 4-years daily driven I guess.

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[Yowie]

As they say on Mythbusters:

"There's your problem"

[Taj]

Gearbox back in yesterday, now that an input shaft seal had turned up (damaged the old one slightly during reassembly). Really easy changeover.

Deleted all the now redundant brackets and wiring for the O2 sensors which reduces clutter down there a bit and gives dump pipe installation a bit more room.

Also, new rear diff bushes for the snout support bit, steering rack bushes and mounts, solid/brass bush shifter knuckle, machined stainless reverse lockout collar made by a friend over in NZ also with a turbo EZ.

That gearbox jack attachment is a godsend! Made it very easy to do solo. Was only $50 or so from ebay.

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[bigBADbenny]

Hopefully the one piece lockout is less likely to rattle due to the extra weight?

If so, I might upgrade…

[Taj]

I'm running out of stuff to do while waiting to be able to put an engine together now...

I made my own header tank for the coolant system to give it a nice high-point / air collection point (now it's with a powder coater so it matches the piping).
I'm really enjoying the AC TIG lately, and I think I'm getting somewhat decent at it!





I also ordered a rebuild/upgrade set of plates and belleville washers for my plated LSD R180 rear diff from Serbia so I'd have something else to keep me busy... That'll give me a nice little side-quest once that turns up.

My clutch arrived back with me yesterday, I sent it back up to Jim Berry for a refresh while it was out. He also changed the diaphragm to a stronger one, it's now set at 4200lb clamp force up from 3400lb. Jim is a real legend... Great price, quick turnaround time, and an awesome teacher over the phone as anyone who's spoken to him will know:


Now I can send the balancer, crankshaft, flywheel, clutch assembly to all be precision balanced together. That should be the last outsourced process before I'm able to start assembling! The heads are looking awesome... can't wait to share a bunch of photos of them.