To adapt the c160 for mr2 usage, the selector shaft must exit from the opposite side of the gearbox.
This means the case has to be drilled for the c60 selector shaft, and a new oil seal carrier must be made and fitted to the box.
I also made a drilling jig to center the hole you need to drill in the casing.
These are the parts I had fabricated :
The tolerance for the oil seal is a bit tight; the ID could be increased by 0.1mm to make the seal an easier fit.
Here is the drilling apparatus : I used a Bunnings drill extension, and linished the chuck end down by about 1/2 mm to be just under the diameter of the selector shaft.
Note the shortened 2.5 mm pilot drill (cut so that the chuck is a snug fit in the internal bush in the casing when the drill touches the case)
Method :
Remove selector assy from c160
dismantle c160 selector mechanism so you can detach the end cap and oil seal
pack gearbox with paper/rags below selector mechanism (to keep junk out of box), while leaving room for the drill bit and extension.
re-fit c160 end cap complete with oil seal.
Grease pilot bit heavily to catch metal shavings
Fit pilot drill bit in extension
Slide drill jig (bush) on extension
Slide the drill assy into the geabox through the end cap (jig/bush should be a snug fit in the oil seal)
Attach drill to extension and drill 2.5mm pilot hole
replace drill bit with (greased) 4.5mm bit and enlarge pilot hole
You should now have a nicely centered 4.5 mm pilot hole through the casing, where the selector shaft has to come out.
Remove drilling apparatus and c160 end cap.
Pack gearbox with rags, as the next step will generate a lot of aluminium shavings.
Turn geabox over, and carefully expand the hole to 19mm (3/4 ") with a step drill from outside the casing.
The oil seal carrier should now fit in the hole you have just made.
to be continued...
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