Chris' other intrac. (lots of pics). Sold :(

Thought i'd give my other intrac a bit of love.
I purchased it with a stuffed auto box. Swapped in the 2wd auto out of my parts car, that was stuffed too.
I gave up on it for a while when I got the crx.
Now the crx is gone I have more time/effort to spend on it. Last week I picked up a l3 gearbox.
This weekend I pulled the auto pedalbox out and got the stuffed auto gearbox out.
Rangi repaired pedal box 794.jpg

I removed the pedal box. (how to thread: http://www.hondacivicwagon.com/bb/viewtopic.php?f=7&t=14032)
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Swapped the pedals across
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Hmm thats not going to work to well.
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Sorted. Safety first
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A quick trim of the rubber boot and bobs your fathers brother
799.jpg.

Next I pulled out a ecu of some description. (pretty sure its for the transmission as it had a Led with a viewing hole in it.
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There was a stud that would of fowled the pedal assembly. I tried bashing it with a hammer
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It didn't work.
Out with my friend MR angle grinder.
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that worked a little better. Needed two runs to get it short enough.
I then bashed the left over stub and it fell off.
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Rangi I know but it did the trick. At this point I noticed the lack of clutch cable hole.
on the outside there is markings where to drill/cut a hole for it so sweet.
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So much rubbish to remove (and compared to the manual one) in-order to drill the hole.
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I didn't have a hole saw handy so I moved onto removing the auto trans.
Last weekend I removed the hub assembily and pulled the driveshaft out.
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Next I removed the front cross member, and front mount. I also got the radiator out of the way.
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Pulled the battery tray and starter off
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Undid the rear stabiliser mount. Removed all the bolts holding the trans to the block. put the jact under the trans and unbolted the last mount. lowered the trans and got this far
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The mount was in the way and the left hand driveshaft wasn't all the way out.
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Removed the mount and with a little bit of brute force and a bit of prying the trans came out.
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The fluid is a nasty colour isnt it? It was fresh when I put the trans in the car.

Just need to pick up the clutch this week and hopefully pick up the shift linkages.
Got a spare flywheel that should do the trick
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couple of pics of the beastie
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The paint is well rooted and he front right guard has a massive dent in it. The alternator bearing is stuffed and makes a evil noise. Piece of piss to change but I'll leave it untill it dies. I love driving POS looking and sounding car in traffic everybody stays away from you.
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Comments

  • SiRgeSiRge Wagonist
    Should be good when it's all going. Wasnt this the one you were trying to sell for ages?
  • rti intracrti intrac Senior Wagonist
    yes it is. noone was interested in it so i'll keep it for a while
  • 1988rt1988rt Senior Wagonist
    nice work, looks like its comming together nice
  • rti intracrti intrac Senior Wagonist
    Today I picked up a new clutch and had the flywheel machined. I got the whole kit for 130 which I was pleased with. Also picked up some springs for it.
    The list of parts I need to get is getting smaller. Just waiting on flywheel bolts and shift linkages. I forgot about the pressure plate bolts but should have something that'll fit. Hopefully the people will get back to me otherwise I'll have to pull them off a car at pick a part
  • rti intracrti intrac Senior Wagonist
    Today I picked up a new clutch and had the flywheel machined. I got the whole kit for 130 which I was pleased with. Also picked up some springs for it.
    The list of parts I need to get is getting smaller. Just waiting on flywheel bolts and shift linkages. I forgot about the pressure plate bolts but should have something that'll fit. Hopefully the people will get back to me otherwise I'll have to pull them off a car at pick a part
    189.jpg
    190.jpg
  • rti intracrti intrac Senior Wagonist
    Flywheel bolts are on their way. Picked up the shift linkage today. I sourced a bearing for the flywheel today. turns out it needs a bush not a bearing so back I go tomorrow to sort that out. 30 mins for lunch doesn't quite cut it sometimes when there are alot of things to do. I'll drop the hub off tomorrow to get teh wheel bearing replaced.
  • danzdanz Wagonist
    the flywheel should use a bearing,not a bushing. just a heads up!

    209.jpg



    Ps, loving the build!! im about to do an auto to manual swap on my wagon too.

    do you know how the pedal assembly differs from a CRX or Civic ? they look nearly identical.
  • rti intracrti intrac Senior Wagonist
    I have the bearing but the hole is too small. apparently there is two types of flywheel bush and bearing. A bush in a manual flywheel seems like a stupid idea to me as the clutch dust is very good at getting into them and wearing the shit out of them.
    AFAIK the wagon/shuttle pedal boxes are differnt to the civic/crx.
    Tonight despite the lack of tools at home I got the auto shifter and torque convertor/flexplate off. I made a attempt to cut the hole for the clutch cable but the hole-saw drill bit was blunt as. I'll borrow some drill bits from work and drill a pilot hole.
    Didn't get any pictures. Tomorrow I'll bring the flywheel and match up the bearing/bushing.
  • smokeyjsmokeyj Band Wagon
    rti intrac wrote:
    I have the bearing but the hole is too small. apparently there is two types of flywheel bush and bearing.

    Okay not to be funny or anything but are you sure you are putting it in on right side of flywheel, I had a friend who complained for a week about bearing not fitting his flywheel the hole was too small I go over and in 5 mins put it in turns out he was trying to put it in on wrong side.

    have you located your mounts for your swap
  • NZ-DB8RNZ-DB8R Moderator
    My Shuttle had a Bearing in its flywheel with the old D Series/L3 box
  • JDMWago666JDMWago666 Senior Wagonist
    The flywheel has to come off to replace the pilot bearing. Push the bearing in on the side that goes against the engine block not the trans.
  • rti intracrti intrac Senior Wagonist
    The flywheel is already out. The hole is physically too small for a bearin. 20mm ID and the input shaft is 15mm. I've found hitachi bushing that works through work. I'll have to trim it down length wise but all other dimensions are the same
  • rti intracrti intrac Senior Wagonist
    Swapped the lowering springs into my spare shocks while the bush was soaking in oil. test fitted the bush and it fits PERFECT!! I'm stoked. Only have to trim the bush length wise now. Photos later tonight. I had the wheel bearing replaced in the hub today so all going well this weekend It'll move under its own power properally. Plan tonight is to bolt the flywheel onto the crank and get the gearbox onto the motor. I just weighed the flywheel. 4.46kg or 9 and a bit pounds. Thats quite light
    Its dark outside already so it should be fun
  • rti intracrti intrac Senior Wagonist
    Got the gearbox in on Tuesday. the right hand side of the car is now all done, wheels on etc.
    I need to find where I put the left hand drive shaft and locate a bonnet hinge and it'll be drivable. Oh and fill the gearbox with fluid. I'm flying down to Christchurch for a friends 21st so wont get anything done this weekend unfortunately. Bring on next week!
  • rti intracrti intrac Senior Wagonist
    IT LIVES!!!! its 11pm and i've just got home. Got it drivable tonight. TOok it for a quick drive down the road. Its the first time in nearly 2 years this has driven properly under its own power. it got about 500 meters down the road and died. towed it back home and no spark. I'll test the dizzy at work tomorrow then put some more fuel in it. Need to bleed the brakes as they are spongy as hell. All going well Friday I can get a warrent of fitness (safety inspection) for it and be back in a wagon!!
  • SiRgeSiRge Wagonist
    Lol, I thought D-series motors never die. They run on hopes and dreams.
  • rti intracrti intrac Senior Wagonist
    It started first pop after sitting outside for months with cobwebs in the intake haha. The motor is good. just the dizzy is probably full of crap. I'll find out after work
  • This is RAD, thank you!
  • rti intracrti intrac Senior Wagonist
    Stripped the dizzy tonight, (i'll do a how to when I get home) coil was well f***ed. I've never seen one that bad. I am amazed it actually ran at all. The cap was buggered and the plugs were well overdue.
    I've got a spare cap at home so will stick that on. just need to swap the bonett hinges over and i'll look like a car again
  • rti intracrti intrac Senior Wagonist
    Got everything done last night. I was up untill 1am. Turns out I had a spare bonnet hinge I found out after I removed it from my good shuttle. I managed to break 2 of the windscreen washer jets and was stealing off the other wagon. The hood catch had rusted up as well. Its heaps of fun driving with the lightened flywheel. There are still a few things to do but is drivable so I'm happy. Just waiting on the call from the mechanic to let me know if it passes or fails the WOF. Will get some pics up tonight
  • SiRgeSiRge Wagonist
    Sounds good! Gotta go for my WOF this weekend, hopefully I can pass... A couple new toys turned up for my shuttle today so cant wait to put them on :D
  • rti intracrti intrac Senior Wagonist
    I didn't have much luck with the WOF. Dent in the floor which I fixed with a few minutes with a hammer haha. trailing arm buses are both shot so i'll have to sort them out. I put the lowering springs in on saturday Happy with the front but quite disappointed with the rear. I also installed my spare facelift bumper and got a good guard to replace the dented one.
    Now for the pictures
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    Flywheel on

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    Clutch on

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    I have alot of respect for you guys wit hno garages because working outsude in the cold sucks big time.

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    Replacement guard/facelift bumper/slamage

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  • 666DAN666DAN Wagonist
    Nice dude!
  • SiRgeSiRge Wagonist
    Trick for the springs what I did was use perches from another car which is a shit load lower, makes the rear uncaptive, but easily solved with extended tophats. Perch went from like a 40mm cup to a more respectable 10mm odd, cheap 30mm drop from nickApart
  • rti intracrti intrac Senior Wagonist
    That was the next step, There was a writeup on NZH a while back about using the front spring perches on the rear shocks, pretty sure it was yours. I have a spare set of shocks so its a very cheap drop. I have to fix the exhaust hanger now it has broken already.
    Today I took the rear trailing arms off with the help of my mate Tim. Tomorrow I'll get them replaced.
  • rti intracrti intrac Senior Wagonist
    This is why it only got 500M down the road
    889.jpg
    I am amazed it acutally ran at all! All it did before it died was missfire a little bit at low revs.
  • SiRgeSiRge Wagonist
    Looks like a quality dizzy, be able to fix it with some tape right?

    I may have done A write up, the problem I found was that the rear shocks were different widthes to front ones. DA rear perches fitted onto shuttle shocks though. But TBH, may as well get some circlip adjustable shocks and get a grove machined quite low, much less pissing round!
  • rti intracrti intrac Senior Wagonist
    Tape didn't quite cut it, Because i'm a tight ass I 'borrowed' a coil out of a spare dizzy at work.I tested it and it worked so in it went
    Much more $$$$ too. I have konis in the silver shuttle which I'll get a few more grooved machined into. This one will (eventually) replace the ute as my daily
  • rti intracrti intrac Senior Wagonist
    Trailing arm bushes were done today so i'll put them in tomorrow when i'm not so tired and with a little luck round 2 with the wof will be a better story
  • rti intracrti intrac Senior Wagonist
    Failed the wof on a few things, no reverse lights. Fixed I used some of the old auto wiring and traced it inside and wired into inhibitor switch. brake pedal too big. Fixed with angle grinder. Wiper blades. fixed. No repeater light on R/F guard. hopefully a wire is unplugged. Brake pedal travel too long. hopefully a bleed will sort that
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