Maxx Mazda's Rebuild Photo Journal

[Maxx Mazda]

For the story go here:

http://www.mazdas247.com/forum/showthread.php?t=123647423

And here:

http://www.mazdas247.com/forum/showthread.php?t=123657671

But anyways, now it's onto the rebuild, so I thought I'd start my own journal a'la Brian MP5T et al.

First off, let's begin with what's planned for the Protege in total over the next 6 weeks. A bit of a "checklist" if you will... (TBI = have already, to be installed.)

- Engine replaced with brand new SpeedCircuit forged setup. Arias 8.5:1 pistons and Pauter rods. Everythign else about the engine is brand new OEM. (Oil pump, water pump, crank, etc.) All wear items replaced OEM, and all gaskets will be Cometic. ARP Head studs.
- AWR Deep Sump Oil Pan
- FS-ZE Intake cam / Mazdaspeed Exhaust Cam (TBI)
- AWR Rad
- Revised MSP LSD, welded (Installed)
- New synchros for 3rd and 4th (revised 2003 ones.) (Installed)
- MSP Clutch Release Fork (Installed)
- FD RX-7 Clutch release bearing (Installed)
- SPEC Stage 2 Clutch (Installed)
- SPEC lightweight flywheel (Installed)
- Split Second AFC II (TBI)
- Walbro 255 LPH pump (TBI)
- 626 Manifold (TBI)
- Magnecor 8.5mm wires
- Corksport downpipe back 2.5" exhaust (TBI)
- Perrin Fuel Rail (TBI)
- WRX 440's (TBI)
- Autometer Phantom Wideband (TBI)
- AWR Side mount inserts
- GTX 3rd and 5th gearsets (Installed)

Planning on running about 16-18psi on that setup, then around 22psi once I get the Microtech, but this as it is has me fairly tapped...

Got the engine pulled tonight, the hardest part was getting the driveshafts out to be honest. What a pain in the ass. Actually removing the engine was a snap. On to the pics, keep checking as I will be updating regularly. Thanks!

 

[Maxx Mazda]

KoolDino sent me a pic of the new block today. As you can see, it's an MSP block, as it has the oil cooler coolant nipple and the longer filter extension for the oil cooler as well. Now those shiny pistons come out in favor of the Arias ones... Mmmmmmm... Thanks again to Dino for all his service.

Edit: Was crusing Protegegarage and he jsut updated it with a pic of a stock shortblock. Compared to the pic Dino sent me, it looks like my block lol! Schweet! My engine will be immortalized! Somebody smack the excitement outta me...

UPDATE: Tonight pulled the tranny off, and removed the clutch, flywheel, windage tray, and oil pan. A few pics of that. Closeup of the oil squirters too in case anyone wondered what they looked like. Laters!

 

[Maxx Mazda]

Got the tranny taken apart, and alot of my parts from Mazda, including the MSP clutch fork, LSD, all new seals and gaskets, tie rod ends, MSP floor mats, etc. Still waiting on the GTX gears. Check out the stock diff compared to the juicy new LSD. Yum!

 

[Maxx Mazda]

Reserved #3

 

[Maxx Mazda]

Reserved #4

 

[Dpwhitehead1]

awaiting.good luck.

 

[Kooldino]

Someone stole your engine.

PS - the driveshafts didn't have to come totally out of the car, but at least they won't be in the way when you drop the new block in.

 

[shane02pro5]

Awesome good luck! Are you doing anything with stronger gears. I will be doing my motor and tranny in the next month or two and plan on trying to find GTX 3rd and 4th along with welded LSD. Do you need to use Mazdaspeed axles with the LSD?

 

[Donas64]

i'm going to be watching this closely. Good luck!

 

[Maxx Mazda]

Awesome good luck! Are you doing anything with stronger gears. I will be doing my motor and tranny in the next month or two and plan on trying to find GTX 3rd and 4th along with welded LSD. Do you need to use Mazdaspeed axles with the LSD?

Keeping stock gears, but upgrading to the revised synchros. Don't need the MSP axles, but you can get them since they're 24mm instead of 22mm. Albeit I doubt I'll break an axle (touch wood.) Also going with the MSP clutch relese fork (it's beefier) and the release bearing from the FD RX7's. It's REAL heavy duty. Don't forget if you don't have ABS, you need to get the LSD machined to accept the speedo gear.

 

[Maxx Mazda]

Second post updated!

 

[Dpwhitehead1]

KoolDino sent me a pic of the new block today. As you can see, it's an MSP block, as it has the oil cooler coolant nipple and the longer filter extension for the oil cooler as well. Now those shiny pistons come out in favor of the Arias ones... Mmmmmmm... Thanks again to Dino for all his service. Pardon the camera phone pic.

Edit: Was crusing Protegegarage and he jsut updated it with a pic of a stock shortblock. Compared to the pic Dino sent me, it looks like my block lol! Schweet! My engine will be immortalized! Somebody smack the excitement outta me...

go you. dana is the s***. my car loves him.


don't understand the writing on the pistons.but cool.and...your block is clean..i wish mine was.

 

[bazooka joe]

looks familiar! good luck man!

 

[Maxx Mazda]

looks familiar! good luck man!

Ha ha ya, go team!

 

[MyZmZm]

cool nick! alice is going to be a beast when you get her up and running. you, jeff and craig should have a little 'get together' when you're all done with your builds and see who's is the fastest!

ps, how much did the synchros set you back? how are they supposed to be better?

 

[Maxx Mazda]

The synchros are a full carbon makeup, instead of the semi-carbon that I had before. It's a late '03MY revision. Send me a pic of the tag on the back of yur tranny (under the bottom) and I'll let you know if you have them or not.

 

[MyZmZm]

i'll do my best and let you know when she goes under the knife in about a month... though the car was originally purchased in late '01, so i can pretty much guarantee they're the 'old' synchros. what are they supposed to do, give smoother shifts or something? i knew the forks were revised (too be stronger), but i had thought the synchros were left untouched...

 

[Maxx Mazda]

Nope. Synchros were also changed to keep from grinding into 3rd and 4th if you shift real fast (like me!) It all depends when the tranny was built. I think it's March 9th, 2002 or somethign was the changeover date... It's in the FAQ. And ya, they did beef up the forks, but they're a pain to change so I'm not gonan worry about it. The LSD is gonna be sweet though!

 

[shane02pro5]

02/02

 

[Maxx Mazda]

Symptoms and Conditions
Customer may experience, hard shifting, grinding, or cannot shift into
or out of 3rd gear.

Condition may be due to the incomplete synchronization of the 3/4 shift
hub synchronizer rings.

Repair Procedure
To improve synchronization, the material of the synchronizer rings has
been changed to carbon.

When rebuilding transmissions built prior to mass production change as
indicated below, install modified 3/4 shift hub synchronizers with the
following part number.

MTX MP Change: March 15, 2002

Synchronizer Part No: GC01-17-26Y (QTY 2)