Kia BP transmission in Z5 Protege

[irishkev90]

Main question is about axles. What could I use? Can I reuse the axles in my car right now or will I have to get new ones?

And what is the transmission code for the Kia BP transmissions? is it the G5M or G5M-R? Just trying to get some more specs like gear ratios and final drive info.

Also, what kind of clutch/flywheel could I run? I'd like to get a lightweight flywheel if I can. Remember, Z5. Not a lot of power so reducing weight would be great and make the engine at least feel just a liiiittle bit peppier.

I think that's it for now. If any other questions pop up I'll make sure to ask.

Thanks guys

[Henchman]

You'll need new axles, but other than that, it will physically bolt up to the z5. Don't ask me about sensors though, I think they should work just the same if you're going from one manual transmission car to another.

[irishkev90]

Nope, automatic to manual.

Oh, and what axles would I need to make it work? He's sending me the driver's side axle, I'm assuming from the BP Kia and the intermediate shaft. Would I just need the passenger's side axle from a BP Kia? If so, what year, model and trim should I look for? Also, will these axles work in my hubs or will I need to do something about that too?

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[irishkev90]

Did some research and compared the Kia axles to Mazda axles. For the record, I used a 1996 Kia Sephia 1.8L (what the transmission is coming from) and a 1998 Mazda Protege 1.5L (what the transmission is going into). Both cars use an intermediate shaft, no ABS and manual transmission.

The Kia's driver's side axle has 28 inner splines and 26 outer splines. The Mazda has 24 and 26, respectively. The Kia's passenger's side axle has 26+2 blank (28) inner splines and 26 outer splines. The Mazda has 26+2 blank (28) and 26 splines respectively.

So the passenger's side axles are the same, spline count-wise, but different lengths. The Kia axle is 24.25" long and the Mazda axle is 22.75" long (.5" difference). The driver's side axles are different spline count-wise and also different lengths. The Kia axle is 24.0625" long and the Mazda axle is 25" long (1.0625" difference). I'm not sure how much of a problem the length difference will be. Maybe someone can shed some light on this factor?

Looks like I won't be needing new axles. The transmission is coming with the Kia driver's side axle and the Kia intermediate shaft. Since there is no spline difference between the Mazda and Kia passenger's side axles, the Mazda axle will fit in the Kia intermediate shaft. Therefore I can reuse my existing passenger's side axle. As long as the different lengths don't pose a problem.

I will keep this updated with information pertaining to putting a Kia BP G-series transmission in a 2nd gen Mazda Protege.

[3ni_tricksta]

what about ecu and wiring harness.

[irishkev90]

Other than the Kia transmission being beefier than the Mazda g-series, they are basically the same. (Still trying to find some information on the internals, though.) Therefore, it's pretty much just another transmission swap. A new ecu is not needed to go from auto to manual and wiring just involves jumping two wires. Here's a pic:


The best pic I can find at the moment. I think Ace posted a better pic of the wire jumping somewhere, though.

And the thread it's from: http://www.wihandyman.com/forum/showthread.php?t=49367

[3ni_tricksta]

are u kidding me? seems like a cake swap then. i can find a manual transmission that came out of our gen protege so easily over here. it's just that i'd have to get a 97 - 98.

btw i msged u on Fb. but oh well.. i'll bring it up here.. are u looking for an entire pedal assembly.. or your just going to mount a clutch pedal.

[irishkev90]

My facebook doesn't like giving me notifications, haha.

But preferably the whole assembly. Or at least a manual brake pedal along with the clutch. Not sure how close the automatic brake pedal would be to a clutch pedal. I don't really want to hit the brake every time I go to shift, haha.

[3ni_tricksta]

i think their's tons of rooom.
you should see if you can just get a clutch pedal for now..clutch pedal is really easy to drop out.. once you take out the clutch cable it's easy to unbolt.
and maybe later on swap out the brake and accelerator.
don't think you'd be touching those anyways during the swap.
i've also never really checked but their should be holes and everything to mount the clutch pedal right?

[Turpro]

Wonder if you can make a hybrid axle. Pro shaft and outer and kia inner so its the same spline on the half shaft end

[irishkev90]

I was thinking about a hybrid axle, but unless the differences in length cause a problem I should be good to go. The Kia and Protege right-side axles have the same spline count, both inner and outer. 26+2 blank inner, female end to intermediate shaft, and 26 splines outer.

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[rusty]

If it is like the escorts pedal assy i would highly recommend getting the whole thing. The escort atx assy will not accept the clutch pedal. There is no mounting point for it. If there is a mounting location then you could always cut down the atx brake pedal to make more room. Could also help with your heal toe response as long as you can get the pedal hight correct.

[Ace]

If it is like the escorts pedal assy i would highly recommend getting the whole thing. The escort atx assy will not accept the clutch pedal. There is no mounting point for it. If there is a mounting location then you could always cut down the atx brake pedal to make more room. Could also help with your heal toe response as long as you can get the pedal hight correct.

Get the WHOLE pedal assembly, all 3. and yeah you don't NEED a new harness and ECU, I did it but I got the harness for free along with the ECU. The wires you'll need to jump go to the inhibitor switch. I'm not sure if they are the same color in the BH protege. But if you can find the wiring diagram you should be able to find out what wires you need to jump(or ideally connect to a clutch inhibitor switch)

[irishkev90]

I'll probably connect them to the clutch switch instead of just jumping them. And yes, I plan to get the whole assembly.

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[irishkev90]

Flywheel/clutch info

I posted this in my build thread, but figured it would be useful here, as well.

*References at bottom*

Well, I checked www.napaonline.com to compare the Miata and Protege flywheels. I used a 1998 Mazda Protege and all four (1990-1993) Mazda Miatas. They are the exact same thing. Here's some info:

Part number: NNC 50913
Number of flywheel teeth: 112
Number of flywheel to crankshaft mounting holes: 6
Flywheel outer diameter: 11.366"
Flywheel step: Flat

This information is identical between the Protege 1.5L and the Miata pages. Though, it does not state an engine for the Miata, which is why I used all four years. Doing some more research I found the Miata FAQ which states for 1990-1993 (no link to the 1991 model) that the engine was "1597cc (97 cubic in.)" or 1.6L.

Well that's it for the flywheel-to-engine problem, now for the clutch-to-transmission problem.

Did some more research on www.napaonline.com using a 1997 Kia Sephia and a 1992 Mazda Miata.

Let's start with the Miata information since the F1 kit comes with a Miata clutch.

Number of clutch disc splines: 22
Disc hub inner diameter/input shaft size: 15/16"

Okay, so how's the Sephia measure up?

Number of clutch disc splines: 20(1.6L) / 22(1.8L)
Disc hub inner diameter/input shaft size: 7/8"(1.6) / 15/16"(1.8L)

Good thing this is a BP(1.8L) transmission. Everything seems to match up.

Now that we know a 1.6L Miata flywheel will bolt to a 1.5L Protege crankshaft, and a 1.6L Miata clutch has the same spline count/inner diameter as a 1.8L Sephia, it should be safe to say that I can use the Miata F1 kit in my transmission swap.

Miata flywheel
Protege flywheel
Miata clutch
Sephia clutch (1.6L)
Sephia clutch (1.8L)
Miata FAQ
Miata F1 Stage 3 flywheel/clutch kit