Shake's Zx2 Build | Page 3 | Ford Escort Owners Association (FEOA)
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Shake's Zx2 Build

Discussion in 'Photo Forum' started by ShakeZilla19, Jun 27, 2019.

  1. marclar

    marclar Moderator Staff Member

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    hard launches, burnouts, any axle/wheel hop, anything that 'shocks' the diff cluster can cause damage. the gears are sintered powder metal, not machined from a solid block.
  2. marclar

    marclar Moderator Staff Member

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    this is what mine looked like... similar id say.

    Attached Files:

  3. novanutcase

    novanutcase FEOA Member

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    One of my concerns in regards to strenghthening the G5 is once you reinforce one area another weak area becomes the weak link in the chain.

    I have read that installing an LSD will certainly make that part of the trans stronger but now you have to deal with the gear shafts pulling apart on hard launches and general abuse of the trans. I know there is a fix for this(plate fix) that is rather costly but will solve that issue but, even doing that, you move onto the next weak point being the case itself.

    There has been mention of an MTX75(?) trans being stronger overall that would swap into our cars. Have you looked at that in regards to the environment the car will be driven in?

    John
  4. krux303

    krux303 FEOA Member

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    MTX75 requires custom axles, new cabling and brackets. Gt35r on teamzx2 did it but it took some work.

    Sent from my LG-H872 using Tapatalk
  5. novanutcase

    novanutcase FEOA Member

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    How'd the rebuild go? Curious how much difference the LSD makes.

    John
  6. ShakeZilla19

    ShakeZilla19 My name is ^^^

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    This is a long post TLDR: The MSP LSD is a hard swap, you need a press w/assorted dies, and time.

    Parts list:
    https://cobratransmission.com/tr5c-synchro-bearing-gasket-and-seal-kit-50132003-1
    Good kit will work on our g-series trans has: bearings, synchros, and seals. ~$150

    Primary Shaft Stake Lock Nut. ~$15
    F520-17-628
    QTY=1

    Secondary Shaft Stake Lock Nut. ~$15
    F521-17-628A
    NEW PART NUMBER: G501-17-629A
    QTY=1

    Speedo Drive Gear; get 2 just incase. ~$17
    G501-17-341A
    QTY=1

    [MSP] Mazdaspeed Protege LSD. ~$450 new
    Differential & Ring Gear
    GS01-27-190A
    NEW PART NUMBER - GSY1-27-190
    QTY = 1

    A 28 spline intermediate shaft . Good luck finding one of these. Pretty sure I found one of the last ones for sell. Maybe you can adapt a long passenger axle with 28 spline inner? ~$100

    mid 90's KIA Sephia driver side axle. ~$30.

    Details:
    The LSD swap has been kicking my ass. Modifying the speedo ring is an iterative process to say the least.

    At first I had hammered the bearings onto the LSD, trust me a hammer does not get the job done... I froze the diff and heated the bearings; no sauce. I could not get either bearing to fully seat as described in the LSD swap guide (that was posted prior). I eventually went to a shop to have them pressed; so far so good. I installed the Diff into the case and immediately had a problem. The speedo ring was way off, as in not concentric to the carriers rotation, it would rotate 180* and jam up onto the VSS gear; Damn. I measured the offset to be about 0.250". I decided, at the time, to file the speedo teeth down. Looked terrible but worked.

    Problem number 2 appeared shortly, I could not close the case with the diff. The bearing on the speedo side was not pressed on far enough. The speedo "tabs" needed to be filed down further. Only way to do that is to remove the bearing. I tried using a press but could only grab the cage (very dangerous) soon after part of the inner race broke off and flew across the room. The bearing didnt even move.. Last resort cut the bearing off and then the speedo melted a little and cracked.

    Attempted to use the old speedo ring but broke it during removal. Waited 2 weeks to receive a back ordered speedo ring and new bearings. I noticed I bent the cage on the other bearing. So I cut it off too. I used the inner race from one of the old bearings to test fit the speedo ring. I would file the ring and test fit multiple times. (this is very important) One of the carrier bearing caps, in the case, had a 0.017" shim. I used the old diff carrier as a reference for the bearing preload. I measured the width of the carriers and the new carrier was about 0.050" wider. I adjusted the preload taking the shim and carrier width into account by using the speedo tabs as a stop. I filed the tabs and test fitted the bearing race then measured depth of the bearing relative to the carrier width. I also had to file other portions of the speedo gear to allow it to sit concentric with the carrier. After many hours the numbers for preload and concentricity were spot on.

    This happened today. I pressed new bearings onto the carrier and tested.. perfect fit, the case closed and the diff spins freely. I have been cleaning trans parts since and lost one of the small roll pins. I haven't found it yet but decided to call it a day. The only other problem is fitting the new intermediate shaft. I think I can just press the new shaft into the Zetec bracket but the shaft is about 1" shorter. I'm going to press it in 1/2" from bottoming out and hope that the extra 1/2" allows both the diff and axle to have good contact.

    I'll keep you posted haven't been taking pics ill get some before I close the case for good.
    Last edited: Mar 7, 2020
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  7. ShakeZilla19

    ShakeZilla19 My name is ^^^

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    LSD in the trans[​IMG]

    Motor is in!

    [​IMG]

    28 spline Kia axles in and fit!

    [​IMG]

    Need to hook everything up, torque bolts, finish the serpentine belt reroute, and install 5th gear.
    ndlm8888 likes this.
  8. novanutcase

    novanutcase FEOA Member

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    Ya gotta be psyched your so close now!

    John
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  9. ChillinZX

    ChillinZX FEOA Member

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    It probably would've saved you time and money if you went with MFactory LSD for the 26 spline G-series during black friday sale when it's $800. You wouldn't have to mess with axles and your other transmission issues. Don't switch to DOT5, DOT4 is plenty good and you melt your brakes before your fluid becomes an issue, besides you CAN NOT mix glycol base with silicone base fluids, meaning all of your components would need to be brand new (lines, master cylinder, clutch master and slave, calipers) since flushing them completely dry would be impossible. You won't have to worry about the G trans until after 350hp, where the steel plate mod would be useful until about 500hp when the mainshaft punches through the bellhousing side, straight cut gears would handle higher then that.
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  10. ShakeZilla19

    ShakeZilla19 My name is ^^^

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    Yeah, I could not fit the MFactory into the budget; this is a $2000 challenge build. I'm pushing the limit for the budget as is and still need to figure/luck out on paint or something. I dont expect to get anywhere close to 200hp with just cams and exhaust lol. After the event I will likely sell the car, as I have a new project waiting in the wings that I'm itching to start.

    As I learned recently DOT 5.1 is glycol based.
  11. ShakeZilla19

    ShakeZilla19 My name is ^^^

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    Installed a 19mm sway bar. Also, mounted some cheap 17in motegi wheels with 215/40 Pirelli P Zero Nero GT tires. They fit pretty well but need to roll fenders for the hard corners.

    [​IMG]

    After stop and go traffic for about 100 miles from the last few days, I did a shake down run tonight. Decent leak from the intermediate shaft looks like I need to push the shaft in a little more... also that wire is too close haha.. other than that the car pulls pretty well. The LSD just wants more, locks up well especially in turns. I cant wait to hit the Auto-x also cant wait to get those cams in it.

    [​IMG]
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  12. ShakeZilla19

    ShakeZilla19 My name is ^^^

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    Well, got the Zx2 running good with no leaks. Had to make spacers for the axle and cut the CV cup down about a 1/4".

    Autox is back locally. Took some video with the GoPro Enjoy!

    austin86 likes this.
  13. marclar

    marclar Moderator Staff Member

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    good progress man. i hate to admit it but i actually scrapped my last scort in exchange for having 2 of my recent chrysler purchases towed home.. ive still got the split port motor, and all my aces saved. gunna rebuild the motor over winter and find a better car to put it in.
  14. krux303

    krux303 FEOA Member

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    Looks like fun! Id suggest getting cam gears and tuning for more low end torque. Wants to rev up so much to get going.

    Sent from my LG-H872 using Tapatalk

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