Chillcast box with 5 speed conversion and type 8 primaries

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nutcase
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Chillcast box with 5 speed conversion and type 8 primaries

Postby nutcase » Sun Aug 30, 2015 9:37 am

Hi All,

been a bit quiet recently with Saab life due to family, but finally getting around to doing a build of something hopefully a bit special. I've only ever rebuilt so far - no conversions.

Basic list of parts is:

79 Chillcast main case with 1992 front case.
New 9.35 final drive/crown assy
As new inner drivers
VGC gearset from 1989 turbo box
New cluster shaft
New bearings througout and gasket kit
New chillcast pinion bearing housing
New genuine crush sleeve
New chains with used type 8 sprockets
VGC tensioner pads
Steel diff cover
New 1/2 shift fork and VGC 3/4 and 5th fork.
New bronze synchro rings for gears 1-4 - can't find any moly coated or 5th ones :(

I see from Jordan's S&R build he is using the original plastic thrust washer - I was planning on using a bronze one as suits the gearset with the locating tag reduced in height to suit the case. Is there a reason I should stick with the plastic one (which have).
Is it acceptable to use the pressed steel cover for the side plate or is there a more rigid alternative available (the later boxes with cast side plates are a different shape of course). I don't mind making a gasket for it but is there a source of them?
Any gotcha's to look out for with using an old case with 89 innards and 92 front case?
There are two types of 5th gear cover, one drilled with a blanking bolt and one undrilled. Any reason not to use the drilled version?

Thanks :)

Will try and sort some pictures as I build, but here's a couple of some of the innards:

Image

Image

Image

Image

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squaab99t
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby squaab99t » Sun Aug 30, 2015 11:01 am

I'm doing something similar with a '78 chill cast and a 5 speed cluster. There is some machining that is required on the main gearbox housing. The housing's layshaft diameter and depth seat are a bit different. Rob at Scanwest is doing the rebuild, but I asked for the case back to do the machining. He said the folks who use to do the machining have either discarded the tooling or are dead :crazy:

I thing the bolt hole you are referring to is the 5th gear indication switch? Rhs down by the skid plate?

nutcase
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby nutcase » Sun Aug 30, 2015 11:16 am

Have you got a picture that shows where you mean for machining? I want to do a dry fit to look for anything like that, but a pointer would be helpful :)

The cover for this aperture:

Image

Do US models have a switch to show when in 5th? What's its purpose?

Thanks :)

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squaab99t
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby squaab99t » Sun Aug 30, 2015 11:21 am

nutcase wrote:


Image



What is the purpose of the extra holes on the bottom of the diff cover?
Image
Last edited by squaab99t on Sun Aug 30, 2015 11:33 am, edited 1 time in total.

KoogiA17
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby KoogiA17 » Sun Aug 30, 2015 11:25 am

Brilliant!

You will have had plenty of practice when I (meaning you) do my 4 speed version of your box. :yay:

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squaab99t
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby squaab99t » Sun Aug 30, 2015 11:44 am

nutcase wrote:Have you got a picture that shows where you mean for machining? I want to do a dry fit to look for anything like that, but a pointer would be helpful :)

The cover for this aperture:

Image

Do US models have a switch to show when in 5th? What's its purpose?

Thanks :)

I'll have to take a picture. Do the dry fit. Take a 5 speed shaft and your 4 speed case. It will have an interference about 1/2 way in. The 5 speed case slides all the way in.

I think the purpose was for the up shift light on the dash. The ecu sent signal to a relay to illuminate the light to help the driver save fuel. The ECU was not smart enough to tell what gear the car was in so they over rid the light as there is no 6th gear.
Eventually it was eliminated and replaced with a plug bolt. My 89 did not have the switch.

nutcase
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby nutcase » Sun Aug 30, 2015 12:01 pm

squaab99t wrote:
nutcase wrote:


Image



What is the purpose of the extra holes on the bottom of the diff cover?
Image


The supplier advised:

" I need to say that there is a “extra bubble” on the plate. Right under if
you hold it against the gearbox. (or lay the gasket on the plate)

It is for mounting a downpipe braket on. Normally it’s mounted against the
side of the transmission but those bolt holes are week, break off very
quick."

I don't think it does any harm so will be leaving it in situ.

Koogi, have you managed to find the final drive yet? :)

nutcase
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby nutcase » Sun Aug 30, 2015 12:16 pm

squaab99t wrote:
nutcase wrote:Have you got a picture that shows where you mean for machining? I want to do a dry fit to look for anything like that, but a pointer would be helpful :)

The cover for this aperture:

Image

Do US models have a switch to show when in 5th? What's its purpose?

Thanks :)

I'll have to take a picture. Do the dry fit. Take a 5 speed shaft and your 4 speed case. It will have an interference about 1/2 way in. The 5 speed case slides all the way in.

I think the purpose was for the up shift light on the dash. The ecu sent signal to a relay to illuminate the light to help the driver save fuel. The ECU was not smart enough to tell what gear the car was in so they over rid the light as there is no 6th gear.
Eventually it was eliminated and replaced with a plug bolt. My 89 did not have the switch.


If you could that would be great :) I'm struggling to picture the exact issue though as the cluster shaft is a sliding fit in the main case? Will have a dry fit of that part earlier rather than later!

I might be wrong but I don't think the UK got shift up indicators - perhaps as manual boxes are the norm rather than auto?

KoogiA17
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby KoogiA17 » Sun Aug 30, 2015 2:32 pm

nutcase wrote:
Koogi, have you managed to find the final drive yet? :)


Ummm.... no not yet. Still haven't found a 4 speed box from the right years. I also need the type 8 primaries at some point plus some other strengthened parts. That's just the box!!

Like you been very busy, but not for the same reasons. ;) Am hoping to make progress end of this year and next year.

nutcase
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby nutcase » Sun Aug 30, 2015 2:51 pm

I did pick up a random lateish 4 speed a while back, still not unwrapped it - I *think* it's a 99 one so not what you're looking for, but if it does turn out to be the one you're after, it's got your name on it.

Type 8's you're on your own :lol:

KoogiA17
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby KoogiA17 » Sun Aug 30, 2015 3:16 pm

nutcase wrote:I did pick up a random lateish 4 speed a while back, still not unwrapped it - I *think* it's a 99 one so not what you're looking for, but if it does turn out to be the one you're after, it's got your name on it.

Type 8's you're on your own :lol:


Thank you very much.

I believe I need to find a box from a mid 80s 900.


I have a set of Type 7s but I do need to protect the box as much as possible, hence the desire for Type 8s, the 9:33 final drive and the resultant longer gear ratios.

nutcase
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby nutcase » Wed Sep 02, 2015 2:49 am

Apologies for the rubbish photo :-(

Image

This is a 5 speed layshaft in the bore - fits fine? I can only assume we're talking about different parts?

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Crazyswede
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby Crazyswede » Wed Sep 02, 2015 10:37 am

nutcase wrote:I did pick up a random lateish 4 speed a while back, still not unwrapped it - I *think* it's a 99 one so not what you're looking for, but if it does turn out to be the one you're after, it's got your name on it.

Type 8's you're on your own :lol:



Somewhere around here we have the 3 part numbers that identify the 3 chillcast 99 4 speed cases. There was an early, mid, and later model each with differences. I am pretty sure we have all 3 at the shop just waiting to be used at some point.
I am the 73%

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squaab99t
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby squaab99t » Wed Sep 02, 2015 10:56 am

nutcase wrote:This is a 5 speed layshaft in the bore - fits fine? I can only assume we're talking about different parts?


Try the gear cluster shaft? About 3/4" in dia.

nutcase
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Re: Chillcast box with 5 speed conversion and type 8 primari

Postby nutcase » Wed Sep 02, 2015 11:00 am

Layshaft/cluster gear shaft are the same thing? This is why I'm thinking we're talking about different parts perhaps?

I'm referring to this shaft (although this is for a late box):

Image


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