Mk2 Kuga Powershift (title edited)

My good friend down the road drew up a CAD drawing for the flywheel spacer and pulled some strings to have it made same day so all good there!.

Pics of the flywheels together, they have decoupled the gearbox at the flywheel now so no plastic mess inside the 2017 gearbox (hopefully)..

Reading into that they knew the plastic was an issue but carried on producing the same design for 9 years which is shocking really..

Bought a plasma cutter to help with cutting out my 10mm adapter plate, even if I have to finish off with the grinder it will save hours of work!.

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A fabulous piece of engineering (y)
I guess the adapter plate you'll have to make is to incorporate the difference in flywheel thickness?
Are you expecting the transmission to be a little harsher, now the plastic holders are gone?
John :)
 
Burnerman said:
A fabulous piece of engineering (y)
Click to expand...
Indeed - I am in awe of engineers, a chap I've known for years trained as an engineer ( Aero engines manufacture) I did his heating for him years ago. Always felt a lesser mortal until I re did his bathroom with him - he was genuinely impressed with stuff I took for granted;) Horses for courses I guess. And when we retire we all mess about in our gardens.;).
 
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Never a truer word Nige!
My engineering studies took me into power station boiler drums and the development of the two stroke expansion chambers courtesy of Yamaha.....a fat lot of use all that is now :(
Time to paint the manhole covers :mrgreen:
John :)
 
Burnerman said:
A fabulous piece of engineering (y)
I guess the adapter plate you'll have to make is to incorporate the difference in flywheel thickness?
Are you expecting the transmission to be a little harsher, now the plastic holders are gone?
John :)
Click to expand...

It's a 2017 gearbox that's going back in not my original.

The engines are different which means none of the bolt holes on the bell housing line up!.

The flywheel is slightly bigger diameter, the new gearbox is deeper to recieve the "new" flywheel".

The spacer is to amintain correct engagement of the centre spline.

He's offered to get me an adapter plate cut but there's that much to work out to maintain the input shaft to crank centrea I've decided to make a proper prototype to make sure it all works properly.

It will be back in one lump if it kills me!.

New 2017 gearbox, spline centre engagement, deeper bellhousing.

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Old knackered gearbox, shallow bellhousing recess so they could fill it full of plastic mess..

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Slow going this week!.

The thread Ford/ PSA used on the crank is 9mm diameter by 1.0mm thread pitch (M9 Fine). Nobody makes a bolt in M9 at 30mm long..

Got quoted £500 for a run of 100 bolts (only need 8!).

After a long hard think I'm going to helicoil the crank to M8 Fine 1.0, use 12.9 allen bolts and sleeve the flywheel and spacer with 8mm ID 9.5mm OD dowels. Tube for the dowels is coming from Canada of all places..

Got my Acrylic plate first cut done, the AWD output and clutch input are the only common datum points on both gearboxes. The clear sheet makes it much easier to get my head around it.

Going to make the adapter plate in 2 pieces I think (top and bottom halves).

Still progress is progress...

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Bit more coffee table .

Interesting bit is under cardboard unfortunately.

Tommorow I'll partially mount the flywheel again, finish cutting the cardboard templates then make sure it clears everything (big ask!).

Plasma cutter and grinder out in afternoon to make my 10mm plate adapters hopefully.

Measure up and order all my bolts.

Long drawn out process but slowly getting there.

Probably only 2013 Kuga in the world with a 2017 Powershift gearbox, no-one else would be daft enough to see it through!.

Cheerss for the comments, keeps me going!.

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Well I've had an eventful couple of weeks with plasma cutters, cardboard, countersink bits and countersunk allen bolts, taps and dies..

Luckily my brackets were spot on and with a bit of effort and help from my mate this morning she's in!.

Gearbox in, AWD bolted back up with custom spacers, subframe back on (with countless connectors!).

Had to order a mounting bracket though, for sake of £25 it's not worth trying to make one..

Next step is trying to code the gearbox to the car, not out of the woods yet but close!.

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I'm almost scared to open your posts now :mrgreen:
Thats absolutely brilliant work!
What happened to the plastic spring retainers on the clutches - have you replaced those?
John :)
 
It's a new design John, the flywheel on the 2017 decouples and damps the gearbox input shaft moving the damper out of the gearbox.

The 2017 has a Euro6 engine, basically the gearbox and flywheel don't fit so I've had to make the adapter plates.

Plus point to all this is I should have a reliable trouble free car (hopefully!).
 
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