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My EGT BP Build Thread

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    My EGT BP Build Thread

    Started taking apart my spare BP05 that I picked up for $50 about a week ago.
    This is going to be the motor I build up as my "Fun" motor.
    The head is currently out at the machine shop getting blasted and the valve guides knocked out (they were frozen in the head). Then I'm bringing it back and doing a full port-match and polish.

    I'm also working on a G series transmission at the same time with a Mazdaspeed Protege welded LSD with new 5th gears.

    Here are the pics so far:



    Taking out the valve keepers with a tool I made out of pipe from the fish-pond filter system lol

    Clamp the valve spring clamp almost as hard as you can clamp it. Then give the retainer a whack with a wooden dowel or a 12mm socket dropped down the pipe, then hit by a wrench. The keepers have been sitting there for so long that they are almost fused with the retainers (since 1992 in this case).



    Keepers....



    Retainers....



    Spring....



    and Valve.

    The Valve Spring Seat is taken out the easiest with a Magnetic Pick-up Wand.
    They will be stuck down with oil and suction.



    An abused motor I'd say. Disgusting. I'm not going to be re-using any of these valves. Otherwise...keep them in order to what port they came from.



    HLA #3 on the Exhaust side is destroyed. It stopped rotating at some point in it's life and has a severe groove ground into it's surface from the cam lobe. It's got the X on it in the pic



    Everything is out. Including all the manifold studs. The head is at the machine shop getting all cleaned and the guides out. Then I'll post more pics of that.


    ================================================== ====


    Here is the bag of goodies for the G Transmission that i got from Mazda yesterday.



    Both of these LSD's are getting fully welded and will be getting speedo seats machined into them.
    They are out right now at "WeirTech Industries" in Burlington Ontario. Reason why I have 2 LSD's is because one if for a ZX2 buddy of mine.

    Stay tuned!~
    Drew
    '95 EGT 1.8
    T
    '93 ELX 1.9 SC
    '91 ELX 1.9

    #2
    Tuned in. picture's a little fuzzy..gotta get the rabbit ears adjusted.
    No car! I soldz it. Now I have a truck. I like it, but apparently it has a hard time keeping up with a slightly modified 4WD protege with half the hp. Neat.

    Comment


      #3
      Sub'n to watch the progress.
      1993 Protege LX-Midnight's shadow SOLD
      1996 Honda CBR600-Wrecked. Damn Honda crippled me
      2002 mazda MPV-family truckster SOLD
      2010 VW routon

      Originally posted by jay
      .....they totally underestimated the number of gearheads such as myself that have families but refuse to grow the hell up and stop playing with cars, or that otherwise see the utility of having 4 doors. Obviously I ain't alone, as there are a helluva lotta sti and evo here. Bueler? Beuler? Mazda? Mazda?

      Comment


        #4
        You are working on the other parts that I am not. You are working on the head and tranny while I am working on the block.

        Good work, cant wait to see it when you are done!
        Block is almost done, cylinders are overboard for Weisco pistons, pro gram billet main caps have been line bored, and my chinese EDT rods have been machined to right specs. Everything has been balanced.

        Comment


          #5
          The block is coming next it's in the trunk of my car right now. lol
          Drew
          '95 EGT 1.8
          T
          '93 ELX 1.9 SC
          '91 ELX 1.9

          Comment


            #6
            looks like what im doing in my apartment! except i can re-use all my valves and im doing all the machining work assides getting the head shaved and the block decked :D

            JACK.
            -Jack

            ONTARIO MAZDA CLUB! Join! https://www.facebook.com/groups/500055016671733/

            91 626 LX - basically stock and pretty slow still
            http://www.clubprotege.com/forum/sho...my-GD-626-LX-)

            01 E53 3.0i - FOR SALE! pm if interested

            91 USDM Protege LX - SOLD! turbo/manifold up for sale!
            http://www.clubprotege.com/forum/showthread.php?t=46606

            Comment


              #7
              Today was Transmission dis-assembly day.

              Make sure you have a 32mm, 26mm (NOT a 27mm that is stated on Imazda), 14mm, 12mm and 10mm sockets. A 1/2" x 6"min socket extension. An Air Rachet and Air Impact Gun are assets. A 24mm box end wrench. A small eye-glass flat head screw driver and a magnetic pickup tool are needed as well. Hammer and punch for taking out split pins and knocking the shaft nut stakes out.



              Take out all the 10mm bolts holding on the 5th gear cover.
              Remember to have emptied the trans of all fluids first....or you are going to have a big mess. Motor mounts have to come off as well (14mm) Also make sure you don't have any axle stub shafts left in the diff. I had one that was stuck...I had to send a flathead screwdriver in from the intermediate shaft side and "massage" the axle end out with a bit of hammer time (can't touch this! oh!)



              Now that you have the 5th gear cover off. Unstake the 2 large nuts that are set into the top gears. A hammer and a punch work well here. Now put a breaker bar/socket on one of the nuts, to hold everything still, while you air gun off the other nut. Now put a rag in the between the gears to jamb them while you air gun off the other nut. This is where the 32mm and 26mm sockets come into play.



              Now use your punch and knock out the split pin in the fork. In this pic is the pin as if I was putting it back in....you knock it in so it falls out under the fork when taking it out.



              Now take off the top 2 gears/syncros that were held on by those large nuts, and put them asside. Take off the fork assembly as well. Care full to not drop everything out of the fork or get the all the gears out of order.
              Now you are looking at the 5th gears themselves.....



              ....and take them off, and put aside.



              Now take off the small bolt on the housing that covers up a small spring and ball. Use the magnetic pickup tool to grab the spring. The ball will probably stay in the bottom...so get your punch...put the magnet on the end (to magnetize the punch), reach down the hole and snag the ball. Put it all aside in order.

              Now...I don't have a pic of it yet....but there are 3 bolts all surrounding the one with the spring. 1 is big (17mm I think?), the other 2 are 10mm. Also use a 24mm box end wrench to take out the reverse switch while you are there. This one in the pic is broken....so I left it.



              Get out your 14mm and air impact gun and take out all of the housing bolts. You will need that extension to do the ones around back.



              Use a flat screwdriver and pry the housings apart using the cast nubs that are right beside the Drain Plug. It should just pop apart. Wiggle it a bit and lift straight up.
              Now. There may or may not be 2 bearing races that fall out when you lift off the housing. Those races are for the bearings on the Primary and Secondary shafts. They are loose, so if they didn't fall...reach into the housing and take them out. Put them aside remembering what they are for. Keep an eye out for any washers that might be behind them. These are shims and must go back in during assembly.
              Last edited by Skuce; 03-12-2008, 09:52 PM.
              Drew
              '95 EGT 1.8
              T
              '93 ELX 1.9 SC
              '91 ELX 1.9

              Comment


                #8


                Drain plug magnet covered in ferrous metal fillings. Pretty nasty. Wipe this guy clean with a mess of paper towels and put it with the rest of the parts.



                Wiggle out the reverse gear. It will be held in there slightly by the reverse lever, so just keep wiggling it. Put the long 10mm bolt that was on the outside of the housing (not the one that has thread only 1/2 way) into the hole in the reverse shaft bracket (so you don't go and lose it). Put it aside. Take the other 10mm bolt that is only 1/2 threads and thread it back into the housing. Just remember that both of those bolts need to come back out at re-assembly time.



                Take out the 10mm bolt that holds the 5th gear/Reverse gear shift bracket on the shaft. Take out the shaft and bracket. Remember to put that 10mm bolt back into it's threads for later.



                Take out the pin that is holding the shift lever assembly in place. Depnding on the age/cleanliness of the trans, You should be able to simply push the cylinder out of the housing. I had to use a flat screwdriver in the slot to rotate the cylinder to break it free enough to push it out. Get in under the main fork to push on the end of the cylinder to back it out.



                Take the body, that the cylinder was riding in, off the spherical pivots and remove from the trans. Reassemble the cylinder/body again and put aside.



                Here you can see the 2 spherical pivots. One on the Fork shaft. One on the shifter rod (that exits the trans and heads to the shifter inside the car) and the hole that the cylinder rides in.
                Drew
                '95 EGT 1.8
                T
                '93 ELX 1.9 SC
                '91 ELX 1.9

                Comment


                  #9
                  Just so everyone is aware. This is a bone stock transmission.I bought it specifically to tear apart for this project.

                  It was used in a Canadian Protege GT for who knows how many years as a beater/daily driver!
                  I didn't clean anything out of this transmission for the pics. It's REALLY that dirty inside. The differential bearing on one end of the diff looks to be seized, since it chewed up the bearing race a bit. The bearings themselves are all pitted and spin rough. I took apart the spider gears in the diff only to find STONES...yes...I said Rocks....wedged in the gear bearings.

                  If you are doing this yourself....and you haven't done regular fluid changes.....don't expect to see shining parts inside. Everything is grey and grungy inside this thing.

                  With the LSD swap. all of the parts that I mentioned above that are damaged in this trans are being replaced. Brand new Mazda bearings/races and obviously new spider gears since a LSD is going in. All new axle, primary shaft, shift rod seals are going in as well (hopefully to prevent more Rock damage! lol
                  Last edited by Skuce; 03-12-2008, 09:16 PM.
                  Drew
                  '95 EGT 1.8
                  T
                  '93 ELX 1.9 SC
                  '91 ELX 1.9

                  Comment


                    #10


                    Now that you have the shift lever/cylinder out. It's time to focus on a small ball catch that rides against the main fork shaft.
                    Use the eye glass screw driver to fit inside the tiny peep-hole and jamb the spring.
                    Wiggle out the main fork assembly.
                    Pick up the ball bearing with a magnetic pickup tool.
                    Remove the eyeglass screw driver.
                    Remove the spring that it was holding



                    Wiggle out the primary shaft. You can move the Secondary shaft around a bit too to get the Primary out. Care full to notice any washers/bearing races that might come with it.



                    Now do the same for the Secondary shaft. But with lifting the diff slightly to let the gears not catch.



                    Now the part that you have been working towards. You finally have full open access to the differential itself. Grab onto it and lift it out!



                    You basically have an empty bellhousing now. The only things left is the one reverse lever. The shifter rod and shifter gate. A couple bearings races and seals.

                    Now that you are this far. You want to take out the old Diff Carrier bearing races and the old axle oil seals. Never re-use bearing races when you are changing the carrier bearings themselves on the diff. If you were just taking the diff out and putting the same one back in with the same carrier bearings still on....then that's different. You would leave the bearing races alone.



                    First you need to remove the Axle oil seals. A big flathead screwdriver powered by a hammer works well.This gives you access to the grooves that let you knock the bearing races out.



                    Now flip the housing over and come at the bearing race from the other side. With the axle seal gone you have more room. Try to knock the race out evenly from both sides. Be careful about not damaging the race seat....it is only aluminum and you are wielding a steel screwdriver here!

                    This should get you to a point where you are almost ready to start re-assembly......almost.



                    There are a few other things to be concerned about first. The Notorious Notch

                    Both of these locations have to be ground off with a Dremel/Die Grinder for the new LSD to clear. The LSD has broader shoulders than the tapered Open Diff


                    But I will get to that during the point where I sand blast and coat the entire bell housing.........






                    Stay tuned~!!!



                    Last edited by Skuce; 03-12-2008, 10:29 PM.
                    Drew
                    '95 EGT 1.8
                    T
                    '93 ELX 1.9 SC
                    '91 ELX 1.9

                    Comment


                      #11
                      Nice work so far! What is the new 5th gear from? zx2, gtx, etc?

                      Subbin' to watch n learn!

                      Comment


                        #12
                        Hey skuce...would you mind if I took some posts and made a how to for the tranni? Or you can make a seperate one with the info. Great ****.
                        1993 Protege LX-Midnight's shadow SOLD
                        1996 Honda CBR600-Wrecked. Damn Honda crippled me
                        2002 mazda MPV-family truckster SOLD
                        2010 VW routon

                        Originally posted by jay
                        .....they totally underestimated the number of gearheads such as myself that have families but refuse to grow the hell up and stop playing with cars, or that otherwise see the utility of having 4 doors. Obviously I ain't alone, as there are a helluva lotta sti and evo here. Bueler? Beuler? Mazda? Mazda?

                        Comment


                          #13
                          That was kinda my intention. Having a "ClubProtege How-to" available instead of there only being a monopoly. I have to go back and re-do a few pics tho before it's all done.
                          Drew
                          '95 EGT 1.8
                          T
                          '93 ELX 1.9 SC
                          '91 ELX 1.9

                          Comment


                            #14
                            060316103 - Primary Shaft Oil Seal - x1 - $6.20ea
                            F00327238B - Axle Oil Seal - x2 - $9.45ea
                            F40117131 - Shift Rod Seal - x1 - $8.70ea
                            F52017628 - Primary Shaft Lock Nut - x1 - $17.48ea
                            G50117629A - Secondary Shaft Lock Nut - x1 - $14.25ea
                            G5R027350B - Diff Carrier Bearing - x2 - $46.51ea
                            G50117341A - Speedo Gear - x1 - $13.41ea

                            That is the list of all the parts I have ordered so far for this....minus the LSD itself. 5th gears are still coming
                            Drew
                            '95 EGT 1.8
                            T
                            '93 ELX 1.9 SC
                            '91 ELX 1.9

                            Comment


                              #15
                              with a tranny that beat up/gross inside, arent you concerned about the synchros being trashed?
                              Escort GTR -- 11.87 @ 117.6 mph -- 320 HP / 325 Ft. Lbs. @ 23 PSI
                              ... The first FWD BG with a Toyota E153 transmission conversion in the USA!
                              Looking for BP x Toyota E153 adapter plates? PM me or contact me on Facebook: Riel Performance Parts

                              Comment

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