draza
29-03-2006, 10:11 AM
This is how to make the MR2 box work in FWD and what axels to use, there was a pic that went with it but i lost it. I hope this helps. This was done for a ST162 now GT2, if trying to put it in to a corolla or something else check that the GT4 outer shafts fit your hubs.
Ingredients:
-MR2 gearbox
-Selector cover and forks from any FWD/AWD E-series gearbox (GT4, V6 Camry, 4AGZE Corrolla).
-Bracket that holds selector levers in place from an E-series box.
-GT4 driveshafts
-MR2 driveshafts
First lets start with the gearbox mods. Ive included a pic of a GT4 geabox to illustrate the parts that need to be swapped over.
Red box: Selector cover
Yellow: Part that needs to be tapped to hold the selectors down.
Purple: Selector levers
Green: bracket for selector cables.
Pink: filter and vent on selector housing
The key to making the MR2 box into FWD is to remove its selector forks and swap it for any of the abovementioned E-series gearbox's. The selector forks in the MR2, GT4, Celica gearbox's sit inside the selector housing. The difference between the MR2 selectors and the FWD ones is that they come out at different ends of the selector housing. The MR2 one comes out just behind the filter and vent. To remove this, You cut the MR2 selector shaft with a hacksaw or grinder just infront of where it comes out of the gearbox as this is only way to pull it out. Then you undo both top plugs, filler and vent, and undo the front selector cover. The front selector cover on the MR2 box has nothing coming out of it and is just covers what will be later replaced by the GT4/Camry item. You then pull the MR2 selector shaft out. Removing the selector forks and cover is easy on the FWD boxes because nothing needs to be cut. As is shown in the picture the screws in the red box and the pink ones are all that needs to be removed. Once this is done, use the GT4/Camry selector cover and forks and push the shaft in, and bolt it up.
Now the problem we have is that there is no holes to bolt in the selector levers (those two bolts in the yellow box are the ones that need to hold the levers in place). You will need to use a clearance drill and tap on the castings on the top of the box to bolt the selectors down casue its not drilled, thats quite simple, just dont go too deep. Then tap it, i think its M10x1.25. Just get a tap same as the bolt out of the FWD box that holsd the selector arm to the casing. In english, u need to make a hole where the bolts should go and tap a thread in it for the bolt to screw in. If you look at an MR2 box, u see the spaces that were left for these holes so its easy to know where to put them.
Now you need to remove the bracket in the green box from the GT4/Camry box and bolt it into the MR2 box. The holes are already there so this is quite easy.
Thats pretty much it.
Driveshafts:
This is the easy bit. The MR2 and GT4 driveshafts can unbolt into two parts- the inner and outer ends. The inner ends are the end that goes into the gearbox while the outers are what goes into the hub (wheel). The two parts are held in place by 6 allen bolts. First u need to seperate the inner and outer ends of all 4 driveshafts you need. Then bolt up the GT4 outers to the MR2 inners... thats all you have to do...
Thats pretty much what needs to be done for this conversion. The only thing remaining is to make sure the engine and gearbox mounts all match up. If they dont, they need to be modified like mine.
Ingredients:
-MR2 gearbox
-Selector cover and forks from any FWD/AWD E-series gearbox (GT4, V6 Camry, 4AGZE Corrolla).
-Bracket that holds selector levers in place from an E-series box.
-GT4 driveshafts
-MR2 driveshafts
First lets start with the gearbox mods. Ive included a pic of a GT4 geabox to illustrate the parts that need to be swapped over.
Red box: Selector cover
Yellow: Part that needs to be tapped to hold the selectors down.
Purple: Selector levers
Green: bracket for selector cables.
Pink: filter and vent on selector housing
The key to making the MR2 box into FWD is to remove its selector forks and swap it for any of the abovementioned E-series gearbox's. The selector forks in the MR2, GT4, Celica gearbox's sit inside the selector housing. The difference between the MR2 selectors and the FWD ones is that they come out at different ends of the selector housing. The MR2 one comes out just behind the filter and vent. To remove this, You cut the MR2 selector shaft with a hacksaw or grinder just infront of where it comes out of the gearbox as this is only way to pull it out. Then you undo both top plugs, filler and vent, and undo the front selector cover. The front selector cover on the MR2 box has nothing coming out of it and is just covers what will be later replaced by the GT4/Camry item. You then pull the MR2 selector shaft out. Removing the selector forks and cover is easy on the FWD boxes because nothing needs to be cut. As is shown in the picture the screws in the red box and the pink ones are all that needs to be removed. Once this is done, use the GT4/Camry selector cover and forks and push the shaft in, and bolt it up.
Now the problem we have is that there is no holes to bolt in the selector levers (those two bolts in the yellow box are the ones that need to hold the levers in place). You will need to use a clearance drill and tap on the castings on the top of the box to bolt the selectors down casue its not drilled, thats quite simple, just dont go too deep. Then tap it, i think its M10x1.25. Just get a tap same as the bolt out of the FWD box that holsd the selector arm to the casing. In english, u need to make a hole where the bolts should go and tap a thread in it for the bolt to screw in. If you look at an MR2 box, u see the spaces that were left for these holes so its easy to know where to put them.
Now you need to remove the bracket in the green box from the GT4/Camry box and bolt it into the MR2 box. The holes are already there so this is quite easy.
Thats pretty much it.
Driveshafts:
This is the easy bit. The MR2 and GT4 driveshafts can unbolt into two parts- the inner and outer ends. The inner ends are the end that goes into the gearbox while the outers are what goes into the hub (wheel). The two parts are held in place by 6 allen bolts. First u need to seperate the inner and outer ends of all 4 driveshafts you need. Then bolt up the GT4 outers to the MR2 inners... thats all you have to do...
Thats pretty much what needs to be done for this conversion. The only thing remaining is to make sure the engine and gearbox mounts all match up. If they dont, they need to be modified like mine.