MITSUBISHI MN196047 & MN130402 - GETRAG 452MT TRANSMISSION

Getrag - Getrag
Model 452MT TRANSMISSION
Picture
Specification
Max.torque  Capacity:  155  N.m
Weight(dry):  32.4  kg
Installation  length:  364  mm
Input  Shaft-Differential:  183  mm

Synchronization
1st  and  2nd  gear:  Single  cone
3rd  and  4th  gear:  Single  cone
5fh  and  R  gear:  Single  cone

Gear  Spread  Ratio:  3.667/4.053/4.158/4.353
Max.  Gross    Vehicle  Mass/Gross  Trailer  Mass:  1200  Kg
Shifter  System:  Cable  shift
Structure
Compact structure, small volume, low weight, NVH performance good, excellent shift quality, big load capacity.

More Links
/removing-gearbox-installation-tips-for.html

Part Numbers - /possible-solution-to-my-cracked-clutch.html

/how-to-change-your-gearbox-oil-in-rcolt.html
/disassemble-fitment-of-z27ag-gearbox.html
/clutch-for-colt-czt-ralliart-smart.html
/czt-rcolt-z27ag-lsd-quaife.html
/lsd-install-z27ag-part-1-getting-box.html

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Kit - 001573.000026 (Sachs Race Engineering printing plate 883082.001573 + CCC Motorsport with torsion organic clutch disc 881861.000026)

Here we have a Brand New GearBox for a Smart Fortwo Diesel Pre 2007, the part number is Q0014208V03000000. These are £1569 Retail From mercedes!

Performance Clutch Cover - Reinforced

Diameter [mm]: 215- Parameter: MF215

manufacturer compare numbers


MITSUBISHI

2304A040

MN196047

SMART

454 250 00 04

A 454 250 00 04

Clutch Disc - Performance

Diameter [mm]: 210 - Number of Teeth: 28 – Transmittable Torque [Nm]: 350 

Torsion damped clutch disc with special organic friction material manufacturer compare numbers

MITSUBISHI

2301A085

2301A090

MN130402

SMART

454 250 01 03

A 454 250 01 03

My Clutch -

Clutch Pressure Plate from SACHS, Article № 3082 000 590

Diameter [mm]215

ParameterMF215

Suitable for MANUFACTURER\MODEL\TYPE KW MANUF. YEAR (FROM - TO)

MITSUBISHI COLT VI (Z3_A, Z2_A) 1.5 CZT 110 03.2005 - ...

MITSUBISHI COLT CZC Convertible (RG) 1.5 Turbo 110 05.2006 - 07.2009

MITSUBISHI COLT VI (Z3_A, Z2_A) 1.5 Turbo (Z23) 113 09.2006 - ...

MITSUBISHI COLT VII (Z2_A) 1.5 Ralliart 110 09.2008 - ...

MITSUBISHI COLT VII (Z2_A) 1.5 Ralliart R 113 09.2008 - ...

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brand   part nr.   part   part info

1   SACHS   3000 951 043 

Clutch Kit

Diameter [mm]: 215

Number of Teeth: 28

See parts list for components:

3082 000 590 ( Clutch Pressure Plate / 1 pieces )

1878 003 232 ( Clutch Disc / 1 pieces )

3189 000 027 ( Releaser (Release module) / 1 pieces )

4200 080 060 ( Grease (high-performance lubricant) / 1 pieces )

2   SACHS   3082 000 590 

Clutch Pressure Plate

Parameter: MF215

Diameter [mm]: 215

3   SACHS   1878 003 232 

Clutch Disc

Parameter: 215VTB

Diameter [mm]: 215

Hub Profile: 20,3x22,1-28N

Number of Teeth: 28

4   SACHS   3189 000 027 

Releaser

Release module   

Parameter: MKB-454

5   SACHS   3981 000 067 

Slave Cylinder, clutch

Actuator   

Transm. Type : Softouch

6   SACHS   6283 007 001 

Slave Cylinder, clutch

Manual Transmission

Parameter: NZ19X55

7   SACHS   6284 000 120 

Master Cylinder, clutch

Manual Transmission

8   SACHS (ZF SRE)   883082 001573 

Clutch Pressure Plate

Parameter: MF215

Diameter [mm]: 215

Reinforced Version:

9   SACHS (ZF SRE)   881861 000026 

Clutch Disc

Parameter: 210 TP

Diameter [mm]: 210

Hub Profile: 20,3x22,1-28N

Number of Teeth: 28

max. transmittable engine torque: 350 Nm

SMART FORFOUR (454) 1.5 BRABUS
(454.034) 130 05.2005 - 06.2006


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More Links
/removing-gearbox-installation-tips-for.html

/how-to-change-your-gearbox-oil-in-rcolt.html
/disassemble-fitment-of-z27ag-gearbox.html
/clutch-for-colt-czt-ralliart-smart.html
/czt-rcolt-z27ag-lsd-quaife.html
/lsd-install-z27ag-part-1-getting-box.html

Le Klaw Bleu - Build #001 of #001- Forged Build Hits the Road

Cross fingers we don't have too many teething issues.










Have noticed the manifold nuts are coming loose, might have to get some cone lock nuts on it.
The small vibrations are shaking them off, or some nice spring washers.







Looks like we have some oil leaking, I have yet to investigate.
New clutch seems to drive fine.
Brakes might be due for a bleed after sitting so long.
No obvious loud suspension noises or bad bearings for sitting too long.

The oracle / wizard / genius is priming the fuel pump and setting base fuel pressure
I dont know what i would do without him













Base fuel pressure of 3km/cm2 ~ 42psi






I am using some stocking to filter out any contaminants still in the water jacket.
I used a denier 7 - Denier may refer to: Denier (unit), a unit of linear mass density of fibers

You can actually buy radiator filters, but i love the touch of ghetto. This will be used for 20mins of engine break-in.










Removing any air in the system.










Bye bye fuel evap cannister crap.

Add we had to tow it home :)
We got very lucky while at the servo checking fluids:
/hks-oil-cap-almost-destroys-forged-build.html

Our break-in procedure:
 - idle between 2000rpm and 2500 until warm - vary throttle - lean out the tune
 - small squirts up to 3000/4000 after warm
 - do this for 20mins
 - drop oil, remove radiator filter (more here), change oil filter and new oil (we use OEM filter)
 - hit the road - max boost 7psi max rpm 4000
 - keep this setup till 1500km - will probably change oil @ 500km
 - some say max throttle 1/4, but i think as long as you are varying and running through the gears
 - use engine braking as much as possible to create a vacuum and pull the rings into the bores
 - check for leaks, fluid loss, radiator water contamination etc

After complete break-in then it will hit the dyno & will try air bleed the lifters (see here)

M20x1.5 SS Hollow Tube - Oil Filter Adapter / Thermal Block Bypass

I got my machinist to knock me up a bypass for my thermal block (oil warmer/cooler).
I worked out the thread was an m20x1.5, just like the oil filters.
BUT for some reason I think the tapped threads in the oil pump were slightly off OR I broke some threads previously and when removing the original bolt it pulled the threads and ruined the rest.

So the hunt for a m20x1.5 tap begun, I didn't need some special HSS bit that costs $80.
I managed to find a cheap set that has all the way to M24 in it.











































Quality of the set seems surprisingly good, its from BORUM importers -
Metric:
m6x1.0, m6x0.75, m8x1.25, m8x1.0, m10x1.5, m10x1.25, m12x1.75, m12x1.5, m14x2.0, m14x1.5, m16x2.0, m16x1.5, m18x2.5, m18x1.5, m20x2.5, m20x1.5, m22x2.5, m22x1.5, m24x3.0, m24x1.5
14 1-1/2” OD Dies
m6x1.0, m6x0.75, m8x1.25, m8x1.0, m10x1.5, m10x1.25, m12x1.75, m12x1.5, m14x2.0, m14x1.5, m16x2.0, m16x1.5, m18x2.5, m18x1.5
6 2” OD DIES
m20x2.5, m20x1.5, m22x2.5, m22x1.5, m24x3.0, m24x1.5
5 Screw Extractors
No#1, 2, 3, 4, 5
1 “T” TYPE TAP WRENCH
1 TAP WRENCH
2 2” DIAMETER DIE STOCK WITH 1-1/2” ADAPTOR
1 PUNCH

HKS Oil Cap Almost Destroys the Forged Build!!!!!!!

The engine turned over today for the first time in a year!


Used a stocking to help filter all other metal that was in the water jacket.


























After a long hard journey, we almost got cursed. I hope all things are smooth sailing NOW.
Looks like the nut on the oil filter attachment bracket spun loose.
Why? Because of shit ass design - where was the cone nut or nylon nut FFS! OR a simple tack weld
The nut bounced into the top right hand corner of the head. SO LUCKY! God know how it ended up there.
The bracket ended up sitting just within a hair on the valve spring.




















How it should look - we didn't have the cut to stop the cap coming loose.

CX5 2013 Rear Rotor Upgrade - 303mm

Shim design, low carbon steel










DBA2549












< A1RM New Pads









Not my own idea, but Full Blast has been doing this kinda thing for ages.
Only now I have found what rotor they could be using.




Fitment: http://minkara.carview.co.jp/
Redrill: http://minkara.carview.co.jp/
More Pictures: http://minkara.carview.co.jp/

ネズー工房 = Nezu workshop / Nezu studio

------------------------ Rear Rotor Info -------------------------------

From Juri:
Yes the brakes are the same on the CZT and the CVR.

I found at that the cheapest method is to get Brakeparts from the Volvo S40 T4 1.9 200hp model. It also shares the same brake system as our colts.

For the front your options are: Disk EBC Turbogroove GD925 (281x25) Pads: are starting with standard pads over green, red, yellow and blue

For the rear your options are: Disk EBC Turbogroove GD854 (250x10) Pads are starting with standard pads over green, red, yellow and blue

The part No are:
Turbogroove Front: GD925
Turbogroove Rear: GD854
Redstuffpads Front: DP31139C
Yellowpads Front: DP41139R
Redstuffpads Rear: DP31076C
Yellowstufpads Rear: DP41076R

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1998-2004 EBC Brakes Turbogroove Discs Rear (GD854).
Dixcel quote the Colt Ralliart rear disc at 250 x 10mm, 114.3 stud pattern, 69mm centre bore,

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So from my understanding we use a disc with these dimensions:
Outer Diam: 250mm (dixcel) / 260mm (volvo)
Thickness: 10mm / 8mm (min)
Height: 40mm
Hub cb: 69mm

EBC REAR TURBO GROOVE BRAKE DISCS MITSUBISHI Spacestar 1.8 99- - Part No: GD854 SOLID - 4 Bolt Holes - Diameter 260mm - Height 40mm - Thickness New/Min 10/8mm

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CENTRIC 120.45083 Rear Brake Rotor/Disc-Premium Rotor-Preferred
P# 120.45083

A Mazda Rear Rotor has these dimensions:
Outer Diam: 303mm
Thickness: 10mm / 8mm (min)
Height: 39.5mm
Hub cb: 68mm
Bolt size: 5 - 13mm
Bolt circle: 114.3

Rear, Qty needed per... 2013 Mazda CX-5 Grand Touring Sport Utility 4-Door 2.0L 1998CC 122Cu. In. l4 GAS DOHC Naturally Aspirated
Rear, Qty needed per... 2013 Mazda CX-5 GS Sport Utility 4-Door 2.0L 1998CC 122Cu. In. l4 GAS DOHC Naturally Aspirated
Rear, Qty needed per... 2013 Mazda CX-5 GT Sport Utility 4-Door 2.0L 1998CC 122Cu. In. l4 GAS DOHC Naturally Aspirated
Rear, Qty needed per... 2013 Mazda CX-5 GX Sport Utility 4-Door 2.0L 1998CC 122Cu. In. l4 GAS DOHC Naturally Aspirated
Rear, Qty needed per... 2013 Mazda CX-5 Sport Sport Utility 4-Door 2.0L 1998CC 122Cu. In. l4 GAS DOHC Naturally Aspirated
Rear, Qty needed per... 2013 Mazda CX-5 Touring Sport Utility 4-Door 2.0L 1998CC 122Cu. In. l4 GAS DOHC Naturally Aspirated

---------------------------- Future Pads ----------------------------

Might try and track down:
ELIG SB511 Compound (TRACK) - (Carbon based compound rated temperature 880C)
http://www.gtpumps.com.au/ELIG_brake.html

In Nov 2013 I did try the pads: /new-track-pads-elig-rs709-evo-1-3.html

They do a road compound for my Evo III twin pots:
 Compound 2021 - VR4/ EVO1-3/EVO RS

---------------------------- Two Piece Rotors ----------------------------

http://www.dixcelaustralia.com.au/2-piece-brake-disc-rotor-assembly