Author Topic: Ashcroft 5 speed conversion (Read 924 times)

MikeLR109 · « **on:** 18 January 2012, 10:59:35 pm »

Hi everyone.
Has anyone had any experience with the Ashcroft five speed box to series transfer case conversion kit
as regards fitting a 200TDi with the kit into a s3 109. I know the engine mounts need moving forward a
few inches, will I still be able to keep the position of the front panel as I don't want to alter the front end
externally, I realise I will have to cut down the back of the panel to squeeze the rad in. Any knowledge
will be greatly received! Cheers.

Sunny Jim · « **Reply #1 on:** 18 January 2012, 11:18:54 pm »

I have one in the cellar waiting to go onto a stubby R380, into an 88". The whole ensemble will be 4" longer than the original.

With a 109, you can move the gearbox back rather than the engine forward, or a combination of the two so you keep the front the same. Even with a Series 3 front, you need a slam panel for the bonnet catch! I am moving the engine forwards a bit and the gearbox back a bit - the exact amounts are yet to be decided! Obviously moving the gearbox means extending the handbrake pull and altering the high/low lever and 4WD plunger, but that is not difficult engineering.

Moving the gearbox means you would need a shortened rear propshaft, which is not desparately expensive. You can either use as longer front shaft or you can use aluminium billet packing pieces to extend it.

You will need a debender type gearbox so the gearlever ends up in a sensible place!

People have said that there are standard props from other models that might fit but having an 88", I don't know any details!

Sunny Jim

MikeLR109 · « **Reply #2 on:** 18 January 2012, 11:32:56 pm »

Ok,
I have all the gearboxy/transfer casey bits ready, but I was hoping to keep
the gearbox on it's original mounts to keep as many parts stock as I can
(slightly hypocritical I know). I was planning on using military style bonnet
to wing clamps and do away with the slam panel type catch in the hope
that I would gain the four inches up front? I think I might do some measuring
to see what I can gain, thanks for the info, cheers.

mistericeman · « **Reply #3 on:** 18 January 2012, 11:36:35 pm »

Hasn't muckypup got a Ashcroft in his

or is his a LT77 ....

Pass ...The Mrs's 88" has a LT77 behind it's TDi engine shunted forward and custom props ...BUT very nice drive

muckypup · « **Reply #4 on:** 19 January 2012, 06:21:31 am »

He has.

It's an LT77 on an Ashcroft conversion. I moved the gearbox back and left the engine where it was, it just seemed easier to me. Custom props and different tunnel arrangement finished the job. I prefer it to 4 speed and overdrive.

mr.scruff · « **Reply #5 on:** 19 January 2012, 09:43:27 am »

Just done this with landyboy and Jim on an 86". Used the same method as Mr. M. Pup and moved the gearbox crossmember back. Looking at the clearances of a Tdi in a Series, not just front panel but axle as well, I'm not sure I'd want to move it forwards?

Have lots of pics which I've promised estwdjhn as well so will post later.

MikeLR109 · « **Reply #6 on:** 19 January 2012, 07:41:32 pm »

Done some measuring today, I can gain the space upfront, but the axle is worrying me.
I have just read on another post that the six cylinder 109 had the gearbox roughly 4"
back, I'm thinking a couple of props from a six pot and move the box back is the way
forwards!

RMS · « **Reply #7 on:** 19 January 2012, 08:19:56 pm »

Quote from: MikeLR109 on 19 January 2012, 07:41:32 pm

Done some measuring today, I can gain the space upfront, but the axle is worrying me.
I have just read on another post that the six cylinder 109 had the gearbox roughly 4"
back, I'm thinking a couple of props from a six pot and move the box back is the way
forwards!

You'll also have to move the gearbox crossmember back and probably cut & shut the bulkhead - that's the way the 6 pot fits in 4" further back

Wooden · « **Reply #8 on:** 19 January 2012, 08:24:51 pm »

Quote from: MikeLR109 on 19 January 2012, 07:41:32 pm

I'm thinking a couple of props from a six pot and move the box back is the way
forwards!

There's a couple of good 2nd hand 6 pot props on the bay at present...

Sunny Jim · « **Reply #9 on:** 19 January 2012, 09:10:12 pm »

I've also modified the pulleys on the front of the TDI to make it shorter and clear the axle better, I already have paralytic springs that raise everything up 2" and those inserts to extend the front bumpstops down a bit!

The advantage of moving the engine forward a little is that the timing pin on the TDI flywheel should clear the crossmember! You can gain 1" from the front panel, using a TDI radiator by simply removing the mounting flange for the series radiator level with the swage at the rear of the slam panel.

With an 88", moving the gearbox back you need a new rear propshaft whatever, so it doesn't matter so much how much shorter it is. With an R380 there are unused tapped holes under the box so it is possible to extend the original gearbox mounts forwards and brace them under the box. These will be in compression most of the time. If you have an ungalvanised chassis, or are fitting a new one, then moving the gearbox crossmember is probably easier.

Sunny Jim

NiteMare · « **Reply #10 on:** 20 January 2012, 03:05:31 pm »

Quote from: RMS on 19 January 2012, 08:19:56 pm

Quote from: MikeLR109 on 19 January 2012, 07:41:32 pm
Done some measuring today, I can gain the space upfront, but the axle is worrying me.
I have just read on another post that the six cylinder 109 had the gearbox roughly 4"
back, I'm thinking a couple of props from a six pot and move the box back is the way
forwards!

You'll also have to move the gearbox crossmember back and probably cut & shut the bulkhead - that's the way the 6 pot fits in 4" further back

just a thought here, wouldn't the bellhousing crossmember in the sixpot also be 4" further back ??

just thinking aloud and it would seem to me to be reasonable to assume it is, never having compared them i can't confirm it though

RMS · « **Reply #11 on:** 20 January 2012, 05:08:43 pm »

Quote from: NiteMare on 20 January 2012, 03:05:31 pm

Quote from: MikeLR109 on 19 January 2012, 07:41:32 pm
Done some measuring today, I can gain the space upfront, but the axle is worrying me.
I have just read on another post that the six cylinder 109 had the gearbox roughly 4"
back, I'm thinking a couple of props from a six pot and move the box back is the way
forwards!

just a thought here, wouldn't the bellhousing crossmember in the sixpot also be 4" further back ??

just thinking aloud and it would seem to me to be reasonable to assume it is, never having compared them i can't confirm it though

Yep, see my post earlier in the thread:

Quote from: RMS on 19 January 2012, 08:19:56 pm

You'll also have to move the gearbox crossmember back and probably cut & shut the bulkhead - that's the way the 6 pot fits in 4" further back

NiteMare · « **Reply #12 on:** 20 January 2012, 05:15:12 pm »

didn't have my glasses on/not enough sugar/coffee/sleep

ok i didn't read the whole thread

RMS · « **Reply #13 on:** 20 January 2012, 05:22:47 pm »

No problem

I know because we considered changing Patrick's Carawagon to 4 pot configuration to put the 200TDi in (was originally 6 pot), but it's on a galv chassis, and Patrick dreams of putting the 6 pot back in one day, when he can afford the petrol

We've squeezed the 200TDi in; loads of room between the pulley and rad, but getting to the starter and injection pump will be a bit of a nightmare as they're tucked up in the cutaway bulkhead.

justamin · « **Reply #14 on:** 20 January 2012, 09:52:31 pm »

I've fitted a 200 Tdi debender engine to an 86" series 1 Chassis and moved the bellhousing crossmember back 4 inches and removed the gearbox crossmember completely, replacing it with 2 mounts welded directly to the chassis. The LT77 sits a little further back than the 4 speeder but its longer and I've had to make custom props. The starter etc is still accessable. I'm currently welding up the chassis' underside and I'll take some pictures tomorow to show whats been done, it that helps. I intend to fit the LT230 with an ashcroft 2wd kit

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Author Topic: Ashcroft 5 speed conversion (Read 924 times)

MikeLR109

Ashcroft 5 speed conversion

Sunny Jim

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MikeLR109

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mistericeman

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muckypup

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mr.scruff

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