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DIY 1UZFE Transmission
Adaptor
Article by
Rod (zuffen)
The
following article explains the process I went through to make an
adaptor to join my manual transmission to my 1UZ-FE. As
part of my conversion I wanted to retain the Rover 5 speed
transmission and 4x4 transfer case. One problem this
conversion raised was the Rover bell housing was 30mm (1.5")
larger in diameter than the Toyota bell housing. As no
commercially available adaptor is made for this conversion I was
forced to have one made or make one myself. I opted to
have a go and see what happened.
I
decided to use 10mm (3/8") steel, I could have used 20mm
(3/4") alloy but space was at a premium and I needed every mm I
could get. I cut two squares out of 10mm hardboard (you
use MDF but hardboard is stronger) and drilled a hole in one to
be a tight fit on the center spigot of the torque converter on
the Toyota transmission. The other hole was made to fit the
Rover transmission. These became my templates.
I
clamped the hardboard to the front of the transmission and
drilled all the holes I would need to bolt the adaptor to the
transmission. I marked which transmission it belonged to on
each template plus which side of the template was the front.
At
this point I had two templates. One had the bell housing bolt
pattern of the Toyota and the other the Rover.
I then
place the templates together (using the center spigot to ensure
they were aligned) and then drilled all the Toyota holes through
the Rover template.
I
reversed the process so I ended up with two templates with all
the holes in the correct place. This gave me a spare should one
be lost or damaged down the track.
One of
the templates was bolted up to the engine to ensure it lined up
and all the bolts would clear each other.
Once I
was happy I had it right I then scribed the outline of the Rover
bell housing on the template. Using a jigsaw I cut the template
to the required shape. I then removed the middle of the
template to allow the ring gear on the back of my flywheel to
fit inside the adaptor
I had
the local steel merchant cut the adaptor using the template as a
sample. Cost AU$70.00.
Once
home the adaptor was tidied up with the grinder to get rid of
some rough edges.
The
template was then clamped to the adaptor and the holes drilled
through the plate using the template as a guide.
At
this point you need to remember the holes that will join the
adaptor to the transmission must be drilled smaller than the
holes in the template to allow them to me tapped for mounting
bolts.
Once
all the holes are drilled and tapped it was time for a trial
fit. Give the adaptor a coat of paint to make it look
pretty and you are done. Everything looks fine so it is
time to assemble the flywheel (it must go on after the adaptor
in this swap), clutch and put it all in the car. With luck
it all works. The secret here is to think before you
cut/drill. Whilst the tolerances you are working with are
quite small it is not critical to be within 10thou of an inch.
This project took me around 10 hours to do.
For a
total cost of AU$70.00 (plus the paint I had hanging around) and
an investment of 10 hours of work I have an adaptor that is
strong, works and I did it myself. Had I owned an oxy acetylene
set I could have cut the steel myself and have the satisfaction
of having made it all myself.
If you
have any questions, please email Rod for more details
garnetts@optushome.com.au
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