Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

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Alucard7002
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Re: Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

Post by Alucard7002 » Sun Jul 16, 2017 9:05 am

Yup, the only thing in the code I can't figure out nor find out is the H on the end.

The KV6 'box is the only PG1 to have this letter on the end. Not even the Lotus versions have it.

My hypothesis is that it stood for Handbuilt.

Seeing the broken circlip and the handwritten "KV6" on the bellhousing makes me think that Rover had the KV6 versions handbuilt in a sideroom. Presumably to tighter tolerances.

I could see no difference between the gearboxes internally nor externally (bar the clutch release arm type)

Anyone else have any ideas?
Dušan

1999 820Si - BRG fastback - FOR SALE
2001 Lexus LS430

Previous:
1997 820 Vitesse - Pewter Grey fastback
2007 Ford Transit 100T350L - White (Duh!)
1993 827 Sterling - British Racing Green fastback
1997 820 Sterling - Zircon Silver saloon

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Re: Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

Post by scoobyh123 » Sun Jul 16, 2017 12:05 pm

I've done a fair bit of digging around in the usual suspects (Wikipedia, aronline etc) and all i've been able to find with any certainty is the Powertrain PG1 gearbox was made by errr....... Powertrain for MG-Rover. At the time, Powertrain were a wholly owned subsidiary of Phoenix Venture Holdings (PVH) so it appears Powertrain only existed between 2000-2005 but i believe Powertrain were in existence before this time as a separate company that built engines and gearboxes for BL, ARG, Rover Group etc.

Given that many of the early KV6 engines were built by hand, Dusans theory of the gearboxes also being built by hand holds a lot of water and would quite probably have had an "H" suffix on their code to denote "Hand-built".

Maybe someone who actually built the early KV6 engines and boxes will join (or has joined) the forum and can tell us with some certainty or perhaps someone who worked either directly or indirectly for Rover will know?
Cheers,
Dave


'94 827 Sterling saloon
'95 827 Coupé LPG
'88 Volvo 760 V6 Estate
All auto :D
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Re: Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

Post by Alucard7002 » Sun Jul 16, 2017 7:33 pm

Sorted!

After a long weekend of gearbox wrangling I have an 800 with all 5 forwards gears and reverse.

More importantly I have one that has good diff bearings! :lol:

A few photos and a couple of videos for you all.

Looks like I only had another maybe 50 miles left before the old gearbox spat the diff out the back - the bearings were BAD.

Image

A way of removing driveshafts without breaking balljoints loose.

Image

Image

https://photos.app.goo.gl/OA14Q5d6j6suSGCC2

https://photos.app.goo.gl/PUfUAtnQLWgFg9ud2

Apologies I didn't realise I'd managed to get oil/munk on the camera lens!

Lots of gear tooth shavings on the magnet along with grey "Self-made neverseize" (aluminium paste)

Image



New gearbox all in and bolted up, quick test drive around the block before getting washed and changed for a run up to the LPG filling station.

The interwebs was correct as was my spreadsheet - 70mph GPS true = ~2400 RPM

Pulls perfectly without labouring, even uphill. Time will tell if it makes a difference to the economy.

Torsen diff is an absolute joy, no more chirruping the inside wheel when nipping out of a junction, in fact you can now boot the thing out of junctions and all you have to do is point it where you want to go and let the torsen do the rest.

Around the twisties it's a whole lot better, especially in the slow speed 2nd gear corners where normally you'd be feathering the throttle to control the inside wheelspin, now you just keep it planted after the apex and watch the Porsche driver's face drop behind you :twisted:

The only thing left to fix is the "dogbone" gearbox mount between the engine and bulkhead as it's perished and squeaking away merrily under high load. Cold cure polyurethane "solid" bushes should do the trick. The other rubber mount on the end of the gearbox has perished completely so will get "upgraded" with a long bolt and exhaust rubbers.

Next job for this summer is rebuilding the spare T16 long block and taking the time to dress it up nicely and paint it.

All for now and fingers crossed for another 128k of gearbox trouble free motoring :lol:
Last edited by Alucard7002 on Sun Aug 13, 2017 7:32 am, edited 1 time in total.
Dušan

1999 820Si - BRG fastback - FOR SALE
2001 Lexus LS430

Previous:
1997 820 Vitesse - Pewter Grey fastback
2007 Ford Transit 100T350L - White (Duh!)
1993 827 Sterling - British Racing Green fastback
1997 820 Sterling - Zircon Silver saloon

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Re: Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

Post by scoobyh123 » Sun Jul 16, 2017 9:09 pm

All good stuff - glad you got it sorted and hope you're enjoying those beers now!

Is there not a "dog-bone" on the Vitty? I know there's meant to be a certain amount of movement in them or it could damage the bulkhead so you may find cold-cure PU is too "solid" for it.

Meanwhile have fun scaring Porsche drivers! :wink: :lol: :twisted: :D

*** EDIT *** I'll have a look in my stash of bits, i have a feeling there's an 820 "dog-bone" (tie rod) in there! :wink: :D
Cheers,
Dave


'94 827 Sterling saloon
'95 827 Coupé LPG
'88 Volvo 760 V6 Estate
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Re: Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

Post by Alucard7002 » Sun Jul 16, 2017 9:42 pm

scoobyh123 wrote:
Sun Jul 16, 2017 9:09 pm

Is there not a "dog-bone" on the Vitty? I know there's meant to be a certain amount of movement in them or it could damage the bulkhead so you may find cold-cure PU is too "solid" for it.
Certainly enjoying the beers!

There is one on the vitty and you read my mind.

I was thinking of using some cardboard tubes to make a poly version of the original bush. That way it still has give in the dogbone but not so much that the entire engine rocks back and forth ~3" under load!

I would also like to play with the rubber engine mounts from the vitty and make up some poly versions of those. Just a little stiffer than OEM purely to keep the driveline shunt to a minimum! :lol:
Dušan

1999 820Si - BRG fastback - FOR SALE
2001 Lexus LS430

Previous:
1997 820 Vitesse - Pewter Grey fastback
2007 Ford Transit 100T350L - White (Duh!)
1993 827 Sterling - British Racing Green fastback
1997 820 Sterling - Zircon Silver saloon

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Re: Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

Post by scoobyh123 » Sun Jul 16, 2017 10:28 pm

I have some ideas about those ideas of yours, kitchen or toilet roll tube would potentially be a good start or perhaps for something stiffer as a mould, some 42mm drain pipe.

I also have some ideas about using thick MDF as the mould material, drill several small holes round the periphery of where the main bush would be so the edge of each small hole touches the area where the main bush is then drill out the centre part to the size you want the main bush to be. This would result in a component that looked like a "bush with bumps"

As for beefing up the Vitesse engine mounts, something they do in the USA is drill holes in the rubber of the original mounts and then fill it with 85 Shore cold cure PU - this results in an OE looking mount but a bit stiffer.

The CCPU can be coloured at the mixing stage with a dye - i currently have blue.................... :wink: :D
Cheers,
Dave


'94 827 Sterling saloon
'95 827 Coupé LPG
'88 Volvo 760 V6 Estate
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Re: Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

Post by CHR15E » Sun Jul 16, 2017 11:34 pm

Pics aren't showing for me?
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Re: Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

Post by traineefarmer » Mon Jul 17, 2017 7:26 am

Is it the larger bush on the dog bone that is perished causing it to thump across the cutouts?

I cured/bodged this on mine but sliding and gluing some 3mm rubber sheet into the cutouts.
Tom.

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'03 XC90 D5

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Re: Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

Post by scoobyh123 » Mon Jul 17, 2017 8:24 am

CHR15E wrote:
Sun Jul 16, 2017 11:34 pm
Pics aren't showing for me?
Nor me - i thought it was my internet playing up again last night so didn't say anything.
traineefarmer wrote:
Mon Jul 17, 2017 7:26 am
Is it the larger bush on the dog bone that is perished causing it to thump across the cutouts?

I cured/bodged this on mine but sliding and gluing some 3mm rubber sheet into the cutouts.
It sounds like it from the description?
Cheers,
Dave


'94 827 Sterling saloon
'95 827 Coupé LPG
'88 Volvo 760 V6 Estate
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Re: Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

Post by mercedade » Mon Jul 17, 2017 10:12 am

No pics for me either!
Adrian
1998 Rover Mk2 820 Vitesse Hatchback (green)
Gone...1992 Rover Mk1 827 SLi Manual (green)
Gone...1998 Rover Mk2 825 Diesel (green)

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Re: Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

Post by Alucard7002 » Sun Aug 13, 2017 7:41 am

Treated the old girl to a good wash, clay and wax yesterday as it was a nice day.

Also hoovered out the inside for the first time in far too long :oops:

Had a bit of a hiccup on Friday with the ;ast working fob dying on me. I borrowed an E-Bike from work to get me home and came back on Saturday morning to swap the ECU, CCU and receiver module over with a matched set with pair of fobs from my spares pile. (Part of R484 NOJ my first 800 lives on!)

Bizarrely the pair of 20 year old fobs from my spares pile work perfectly yet the '98 and '03 fobs original to the 820 when I bought it are both knackered. I'll be sending them to a friend with a reflow oven and hopefully he can revive them.

Before

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After

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Still Orange peely but passes the 10' test.

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All for now
Dušan

1999 820Si - BRG fastback - FOR SALE
2001 Lexus LS430

Previous:
1997 820 Vitesse - Pewter Grey fastback
2007 Ford Transit 100T350L - White (Duh!)
1993 827 Sterling - British Racing Green fastback
1997 820 Sterling - Zircon Silver saloon

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Re: Alucard7002 - Mk2b 820Si Fastback - Pic Heavy!

Post by scoobyh123 » Sun Aug 13, 2017 8:07 am

Looking good! Lucky you had those spare ECUs/fobs! :wink: :D
Cheers,
Dave


'94 827 Sterling saloon
'95 827 Coupé LPG
'88 Volvo 760 V6 Estate
All auto :D
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