My Ke55 Project

[drc_ke20]

the car looks 100 times better than you 1st got it!

those 17" rims looks sweet and so shiny!

well done!

[ke20rolla]

Well got my 5k motor back from the machine shop today. Fully rebuilt, bored, new pistons, oil pump, bearings, shaved head, new valves, the lot. Should have a bit more power than the old 4k. Also got a excedy heavy duty clutch kit for it. Had to get it made up, as the 5k clutches are 200mm in diameter compared to 180mm 3k and 4k's and the 5k's are 21 spline and the 4k's 19 spline. So what they did was put a 4k center in a 5k clutch. Should be putting it in this weekend if all goes well. :lol: :wink:

[leigh]

Well got my 5k motor back from the machine shop today. Fully rebuilt, bored, new pistons, oil pump, bearings, shaved head, new valves, the lot. Should have a bit more power than the old 4k. Also got a excedy heavy duty clutch kit for it. Had to get it made up, as the 5k clutches are 200mm in diameter compared to 180mm 3k and 4k's and the 5k's are 21 spline and the 4k's 19 spline. So what they did was put a 4k center in a 5k clutch. Should be putting it in this weekend if all goes well. :D :)

 

 

Hows it all going mate? Get it in! ??

[Taz_Rx]

Well got my 5k motor back from the machine shop today. Fully rebuilt, bored, new pistons, oil pump, bearings, shaved head, new valves, the lot. Should have a bit more power than the old 4k. Also got a excedy heavy duty clutch kit for it. Had to get it made up, as the 5k clutches are 200mm in diameter compared to 180mm 3k and 4k's and the 5k's are 21 spline and the 4k's 19 spline. So what they did was put a 4k center in a 5k clutch. Should be putting it in this weekend if all goes well. :D :)

 

Numpty....you should have just put a 3/4k flywheel on it!!!!

 

So how much did the full rebuild cost if you don't mind me asking?

[ke20rolla]

The 5k flywheel would be heavier i take it. I wanted to keep it all stock, rather than mix and matching bits. The full rebuild including diss-assembling and re-building with all new parts including new oil pump, valves, pistons etc and everything machined and aligned came to about $2300, which was trade price. :P

Have got the motor in and just have to add oil and water. But now have the gearbox out as it has a crack in the bellhousing, Getting it welded up and hopefully will have better luck when I put it in. :lol:

 

What I think has happened is that the spiggot bush wasn't pushed all the way into the crank, and when I put the motor in I had it located in the dowels and just pulled the extra 3mm gap up with the bolts. And as I was doing this the gearbox was trying to press the bush in more and therefore putting pressure on it and the rest is history. :hmm:

[Taz_Rx]

Well you've now got a mix match of corolla/liteace parts in your drive drain.

 

The reason it had the 200mm clutch diametre FW is because its as it came from the liteace. FW itself is identicle apart from the bigger contact area. Using a corolla 180mm FW means you could just use any regular corolla clutch kit. Can't use a liteace clutch kit as the input spline is massive compared to a K40/50.

 

Not a huge drama, just something to keep in mind should you want to put a lightened FW or something in later.

[ke20rolla]

Got the gearbox fixed. I found out that the problem was the pressure plate was to big for the bellhousing. I went back to pabs and they said that there is a difference between ke55 and ke70 boxes. I went home and looked at a ke70 box that I had in the shed and it has a much bigger bellhousing :( . So what I have done is put the 4k flywheel and clutch on the 5k and used the original ke55 box. Got it all bolted up and put the water in the radiator and oil in the motor. :y: :P . Started it up and got it running and turned it off to check water and oil, And noticed oil pouring out from between the back of the motor and the gearbox. :hmm: :) :n: :( . Checked the gearbox oil and it hadn't gone down, but the engine oil had. Going to the machine shop on monday to find out what is going on. :hmm: :hmm:

[leigh]

Aww bugger about the oil issue mate! :) hope u get it sorted!!

[Taz_Rx]

hahaha been there done that Mark!!!

 

I tried to use a KM (liteace 200mm) FW and a T18 clutch kit for the T50. Spend $400 (trade price) on a clutch kit and tried to assemble it as it all worked on paper. Shame I did think about the pressure plate as 200mm one fouls on the inside of a K-T bell housing, let alone a K40/50 one. :)

 

200mm pressure plate will only fit inside a K-W bell. :)

 

Spewn about the oil. Hopefully its just a dodgy rear main seal and they'll fit it for free. Just a bummer you've gotta take the engine out and clutch FW etc off again.

[ke20rolla]

Hey Simon, the 200mm pressure plate will fit in a ke70 box as they have a bigger bellhousing. I know this because I have an old wornout ke70 box in the shed. :)

[Taz_Rx]

Whats the casting in the bell housing around the clutch fork like?

The PP fouled on the flat spot around this in my K-T.

[ke20rolla]

Will have to have a look. But there was heaps more room. :D

Got my motor out again, couldn't see anything obvious. They are going to pick it up and have a look at it tomorrow. They bought me another clutch plate as mine was covered in oil.

So I will have to wait and see what they find.

Edited May 13, 2009 by ke20rolla

[ke20rolla]

Hi all, just an update. I have got my 5k motor in and is running well, I took it in to Berklee today and got a 2inch sports exhaust system made and looks great. :hmm:

But I'll be taking it fairly steady as I need to run the motor in. :D :dance: