jlumba81

I used a Pro-werks C73-750 2" Black Aluminum Fill Cap with Steel Weld Bung. They have a few other sizes. I believe I used 'weld bung' when searching amazon. athens7- Thanks for reminding me. I think I'll make a dipstick when I replace my leaking speedogear oil seal and my fuel filter. I ended up getting the fill cap instead of an o2 bung because I'd have to order an o2 online and I wanted something w a bigger opening.

While I was at it I cut down a 10mm allen fit the transmission fill plug. Paper gasket for the trans cover broke in half. Used some axle rtv that was lying around to make a seal Trans cover reinstalled. Two rear bolts are a PITA. Also don't forget to keep track of all bolts when removing the cover. I counted 9 and thought I dropped one in the trans, but found it on the side of the transmission. Using pump siphon to remove the old fluid. Made a mistake and put redline 75w-90 GL-5 oil and had to remove it. Ended up buying some royal purple 75w-90 oil GL-4, GL-5 rating until the proper GL-4 oil arrives next week.

Magnet to hold filler cap bung in place I need more practice its a bit messy but it works. Filler cap fitted to bung Rattlecan black for rust prevention

I decided to follow the advice of a fellow 7 owner to install a filler cap on the T-9 cover. Filler cap off amazon.com for $35 Filler cap placement on trans cover Pilot hole drilled Need a better hole saw but it got the work done Cleaned up the hole and prepped area for welding

yeah I ordered it from burton power on may 18. Still waiting on the parts.

Anyone have a part # for the T-9 5 spd speedo gear oil seal? I'm getting a bit impaitient waiting for my order to arrive from the uk and have everything else to do it. Part # that will work at napa, o'reillys, or rock auto. Thanks. Well just recieved the oil seals today. I'll try bringing them to napa and o'reillys to see if they can match them up. I'll post the parts #s if I can get any.

Wilwood might be a good alternative. http://www.wilwood.com/MasterCylinders/MasterCylinderList.aspx?minorname=Integral Reservoir Compact Master Cylinder

You could try taking the bonnet off and misting some water on the electrical parts to see if it stumbles or misfires at idle. Might be a problem w moisture getting in the coil. Check for cracked insulation on electrical parts. Could be the hard driving is drying out the faulty electrical parts.

bsimon, what's the tyipical mileage before a caterham ujoint fails? I don't have a shop locally that does auto driveshafts. I'll have to look around to see if a boat shop can do it or just ship it out to get it worked on. Probably be a fall/winter upgrade.

Is the top cover removable w/ the transmission still in the car? The welded bung tip sounds like a good idea. I've also seen aftermarket alloy top covers w/ fill holes going for around $85. How do you take off the transmission tunnel cover off the ebrake handle? Saw the alloy lid on this site: http://www.bearingkits.co.uk/product_info.php?currency=USD&cPath=76_90&products_id=401&osCsid=fad5779367dc63fc0b4638e1982cd515

Well just came back from a quick run to home depot. Under very light throttle there's a grinding noise, but it goes away under more throttle. So I think it may be the diff going bad or in need of adjustment. Anyone know where to get a diff rebuild kit and/or shim kit? And just in case a new ring gear/crown wheel and pinion? I'll have to wait for some good weather until I can pull out the diff to check the backlash. Does anyone have a backlash spec handy? Hmm...just did a google search and it seems that some differential noise and backlash is normal. Well I guess the only way to make sure is to open it up and bust out the marking compound and dial gauge. Always more questions popping up. What's the reccomended fluid for the diff w/ a lsd?

It clunks in all gears. I still need to look at the motor and transmission mounts. I'll probably take a look at the diff cause I want to check out the fluid level. I have seals for the speedo gear coming in and redline mt-90 gear oil. So far I've been driving the 7 everyday to work except for 1 week where it was all rain and I didn't have the full weather top yet. Next upgrades I plan on doing are some heat wrap on the headers and some insulation on the pedal box. Thanks everyone for the feedback.

Well I ended up ordering the speedo gear oil seal from burtonpower.com. I ordered an extra so I have something I can take to the local auto parts store to match up in case I need another one.

I had the 7 up on jackstands and used a 24" prybar to check the bushings. Still need to check the engine mounts and transmission mount.

'04 SV zetec svt w/ t-9 5 speed. There's a clunk when I upshift that I haven't been able to track down yet. I've checked the driveshaft ujoints and the rear suspension bushing and there wasn't any movement. Also have a minor leak from the transmission where the speedo gear goes in. Can anyone give me a part # for it or know of a website that has them? Also how do you check the fluid level on the transmission? There were several posts about taking the top plate off, but it looks like on the SV the plate is right under the firewall.

I recently bought a set of Hella H6024 7" Round E-code Hi-Lo Conversion Headlamp Kit. I ended up bending the retaining springs a bit until they held the headlamp properly.

Thanks for the quick reply. I forgot about QA-1s, I'm familiar w/ them from the Extreme4x4 tv show. The Proma Star single adjustable shocks look interesting. What length of shock did you end up getting? How is it w/ the spherical bearing vs a poly bushing? Any excessive wear from dirt and dust getting in the bearing?

Anyone know of quality adjustable shocks for the 7 that are rebuildable in the US/North Amercia? Most of the adj shocks I've seen are from UK or German. I might end up getting a set of 1 way adjustable nitrons, but was looking for more options.

I'm locked in at work til the summer rush is over. I don't think I'll be able to go anywhere this year, I need to start making payments on the 7 soon. I hope to go to Anchorage next year and go to an autox event. What's the route for the Grizzly Bear blat? I recomend the Skagway pass into canada. It was amazing w the frozen lakes and the 20+ ft deep snowfalls. There were snow boarder and snow mobiles everywhere.

So how much for the hood and bag? Could I also get a shipping quote to 8837 Gail Avenue Juneau, AK 99801 If it can fit into one of the USPS pritority boxes that would probably be the cheapest and easiest to do.

Oh the new owner is me. I'll post about the trip when I get over the fatigue. Croc is right on the money w the 4k. It was supposed to be 3700 but getting lost added a few miles. Ended up leaving Jersey City, New Jersey on tuesday around noon and ended up in Skagway, Alaska Sunday around 10a.

As of last tuesday April 19, I am the proud owner of Mike aka Croc's zetec powered SV. If anyone has a full weather top they aren't using let me know. Rain storms aren't much fun in a soft bits half hood.

Question on the hella horn placement having one pointing towards the driver. I find my hella horns to be fairly directional. Its hurts when your in front of them but not so bad angled off of them.

The hose looks like it has a crimped on band hose clamp. You can just get a screwdriver in there and spread apart the crimp til its loose and the hose should come off. If you have a crimp tool you can recrimp it or just replace it w a screw on hose clamp that you can find in any autoparts store. Other than that hopefully a 7 owner can give advice on the other questions.

Looked at some of those fsae build videos and its amazing what they are doing. Using autoclaves and making carbon fiber bodies and parts, milling their own parts, etc. Also some neat turbo and supercharged bike engines. Also using cfd to design their floors, diffuser and wings. Neat stuff. Here's a nice promo video from the university of washington -