Jim 123 Posted October 13, 2015 Share Posted October 13, 2015 I will be building an S3 Kit in the near future. I have ordered a 1.6 Sigma Engine with 5 Speed Box. The Build Manual states that the Engine and Gearbox should be connected together, and then both should be dropped into position using a hoist - Pretty obvious I suppose. However, a couple of different sources, who are experience in working with Caterhams, have said that it is easier to fit and centre the Gearbox first, and then afterwards lower the Engine into position. The Engine can then be bolted to the Bell Housing before the Engine Mounts are torqued down.With my workshop, things are going to be space and height restricted when it comes to dropping in the main power train. I'd appreciate any advice on the 2 courses of action open to me please. Link to comment Share on other sites More sharing options...
DJ. Posted October 13, 2015 Share Posted October 13, 2015 Hi, I built a Sigma 125 inside a small size Airchamber, so don't worry you'll be able to do it.I had a height limit too, so I changed the build order, so I had a rolling chassis before installing the engine with the gearbox. With the car on its wheels you can move the car as well as the hoist and it is much lower than on axle stands.Mating the engine to gearbox can be quite tricky lining up the gearbox shaft, so would be easier outside the car. Remember to put some sealant on the paper gasket that goes between the box and bell housing. Duncan Link to comment Share on other sites More sharing options...
Martin J Posted October 13, 2015 Share Posted October 13, 2015 I did exactly the same as Duncan & had a rolling chassis first & then fitted the combined engine & gearbox.I didn't however build it inside a bubble like Duncan. Link to comment Share on other sites More sharing options...
Nillbymouth Posted October 13, 2015 Share Posted October 13, 2015 One thing to consider if fitting the gearbox and engine together, I was given a platic plug by Caterham to fit the propshaft end of the gearbox. This let me fill the gearbox with oil before fitting to the car which saves a lot of hassle trying to fill it once fitted. Hopefully these two photo links will work:Once fitted, I also taped the plug so that it would not fall out! Link to comment Share on other sites More sharing options...
DJ. Posted October 13, 2015 Share Posted October 13, 2015 http://i1170.photobucket.com/albums/r538/underhay/003_skcc/engine_installation_3.jpgHere's a picture of the engine going in, the load leveller is a great piece of kit.One more thing, remember to put the prop into place before fitting the diff. I don't think you can do it afterwards! Link to comment Share on other sites More sharing options...
Jim 123 Posted October 14, 2015 Author Share Posted October 14, 2015 Guys, many thanks for your great feedback and photos.With the benefit of your experience, I am much more confident about how to proceed and also how to aviod painting myself into a corner! Link to comment Share on other sites More sharing options...
John Vine Posted October 14, 2015 Share Posted October 14, 2015 Another vote here for installing engine and gearbox together. I'd also strongly recommend a load leveller -- this photo shows just how versatile it can be.JV Link to comment Share on other sites More sharing options...
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