Disassemble & Fitment of Z27AG Gearbox 4G15 Getrag 5spd - Part 2

After many months of finding parts and trying to sort out the gearbox I finally got there.
It all started when i broke the housing at the drags @_@
/gameover-virgin-drags-14991s.html

Could be a bunch of reasons why it happened.
At this time I had a spare gearbox. But that also had a damaged bell housing @_@
I discovered by pot luck that I could buy a new bell housing! I was saved!
/possible-solution-to-my-cracked-clutch.html

I then bit the bullet and thought about building a second gearbox to swap in. So I started looking at what i could modify while the gearbox was getting swapped. It started with a lightweight flywheel from RRP.
I also changed the rear main because that had been leaking for a long time.
Then the hunt begun for another LSD. This time clutch pack.
/czt-rcolt-z27ag-lsd-quaife.html





I accidentally found a ATS carbon diff for sale. Its for a mini cooper. But according to my studies it should be a perfect fit! I got excited!
I did more research /lsd-ats-carbon-cbfb8710.html
and before i knew it, it was at my door step.
/my-ats-carbonetic-cbfb8710.html











Then the autopsy of the old gearbox was in order. I had no idea about the condition.
So far seems good, its in the car and shift. First and third are tight. No idea why.













Half way during the rebuild i realised that the bell housing i bought doesn't contain any of the bearings or input shaft seals.
I started removing them from the old case /gearbox-parts-lists-rebuilding-my.html
and so the rebuild begun


/disassemble-z27ag-gearbox-4g15-getrag.html








After 30mins of driving i changed gear fluid.
It smelt like kerosene. Apparently the cast will absorb the kero that i used to clean the gearbox with














































































Looks like i have uneven wear on the clutch disc/pressure plate.
No idea why @_@


Various torque setting:
 - Top engine mount bolt and nuts = 43+/-4Nm
 - Starter motor = 24+/-3Nm
 - Bottom engine mount three bolts = 58+/-6Nm
 - bell housing bolts = 48+/-6Nm
 - bell housing bottom cover (bolt that go into the gearbox) = 23+/-4Nm
 - bell housing bottom cover (bolt that go into the engine block) = 48+/-6Nm
 - LSD ring gear bolts = 85+/-5Nm
 - 18 gearbox torx bolts = 27+/-1Nm
 - clutch fork torx bolt = 10 +/-1Nm
 - Clutch cover to flywheel bolts = 18+/-1Nm
 - Flywheel bolts = 132 ± 5
 - Rear oil seal case = 11 ± 1

Suspension and axles:
 - Strut Assembly (top hat bolts x 3) = 44 ± 5Nm
 - Strut/Knucle connection = 88 ± 10Nm
 - Bolt (Lower arm and cross member connection) = 123 ± 12Nm
 - Nut (Lower arm and crossmember connection) = 123 ± 12Nm
 - Lower arm assembly ball joint = 60 ± 6Nm
 - Swaybar linkage = 30 ± 5Nm
 - Swaybar stabilizer bracket to cross member = 50  ± 10Nm
 - Tie rod to knucle connection = 25  ± 5Nm
 - Axle nut = 245 ± 29Nm
 - driver side axle cover (holds axle to engine block) =  23 ± 3Nm


---Lightweight Flywheel---
Colt version aimed at the accelerator response of R, we have developed a lightweight chromoly flywheel of dedicated products.
It is a balance that brings the best finish in ultra-precision machining response and the taste is not normal.
We aim to response on par with car NA.

Have specifications that even though lightweight, with reduced rotational inertia weight to concentrate to reduce the weight of the outer peripheral portion, further up the response you can expect.

Down 32% from normal weight also! I also consider the weight setting of ease of use.

Also consider compatibility with Getoragu mission, because it is made to consider the balance, weight, and materials, you can rely on.

Because it corresponds to genuine clutch is also possible when you replace the clutch replaced at the same time in maintenance.

☆ 32% made of lightweight 4.5 kg 6.7 kg → RRP normal
☆ painted products corresponding billet chromoly rust
Already fully balanced ☆
☆ Designed for normal clutch

Colt lightweight chromoly flywheel for RRP: CoD-100 - 46,200 yen