S2 transmission swap

[SENC]

Found the purchases on Ebay history, but not much detail there.  These had the same 7-1/4" clutch as the Anglia and Mk1 Cortina, as I recall.  Borg & Beck/AP.  Will keep looking and post if I find anything useful.

[SENC]

24 minutes ago, Christopher smith said:

That sure looks like a different spacer ( dust shield? but similar bolt pattern and dowels to my 122E -6015 block which I thought was a Cortina GT MK1 ( rope seal crank)and thought that was what Cosworth was using back then. Or is yours an earlier 1340 3 bearing maybe?

No, mine is a 1500 Cosworth.  No idea if the one I replaced was original, but it very well could have been.  From the history I have on the car, I'm pretty confident it wasn't replaced post early 80s.

 

Here is a pic just out of the car.

[MV8]

11 hours ago, Christopher smith said:

Did those gearboxes ( some originally column shift maybe?) employ clutch covers with the 3 finger design and maybe ? 190 clutch disc with what spline count? or the newer ones with many fingers  and if so , flat or curled? Maybe the newer ones were Cortina MK1? I am certainly getting something wrong with my newer Saab and or Tilton concentric slave cylinder set-ups. It seems to work fine before starting the engine. Releases and engages multiple times just fine. But with engine running, depressing the clutch pedal a few times and it pushes the T.O.  bearing way too far out and locks in that position somehow. I can then back off the bell housing to block bolts and the fingers push the T.O. and slave cylinder back the way they should be doing. Maybe misaligned?

It sounds like the slave is being slightly over extended. Looking back at your clutch mystery topic, I see you are missing the rubber dust boot that keeps the area of the slave clean where the release bearing boss slides back and forth on the slave main body that bolts to the transmission and the release bearing. Not critical but worth having and typically included in a replacement slave. Maybe it could not be used due to this being an adaptation?

 

Also, the slave has limited travel so where it starts from matters. If the slave is shimmed away from the trans, the release bearing will not be as extended on the slave with the pedal to the floor. The slave should not be shimmed tight to the clutch to where the release bearing cannot be pulled away from the clutch at all. This gap is what allows the slave to self adjust to clutch wear.

 

Compare your old/spare slaves off the car (pushing and pulling to find range of travel fully extended to fully compressed. Try to see how that compares to peering through the bell. If it is a half inch or more from fully compressed when the release bearing is touching the clutch, I would definitely shim the slave away from the trans by an 1/8 to a 1/4 inch or so with either washers or fabbed shims. Looking at a Saab 900 slave, I see it is not flat. The contact point between the slave and trans is what needs to be shimmed. That could be any of these colored shims.

 

It could be you've eliminated lost motion that was present in the system before you first took the car apart, combined with it being a new clutch system that slightly changed the location of the pressure plate levers relative to the slave.

 

Edited November 30, 2025 by MV8

[MV8]

As for a 190mm / 7.5" x 23T x 1" clutch, I'd change flywheels or redrill the old one to accept a thin, 8.5" diaphragm pressure plate (for bell inside clearance if needed) and common replacement clutch discs.

[7Westfield]

On 11/29/2025 at 6:30 PM, Christopher smith said:

The input splines and diameter and output as well?

input on the type 3 I removed is 7/8-20

output is smaller than T9

if you need that number, I can go dig it out of the shed

 

If getting a BH from a Pinto, it must be a 1600 or 2L     2.3L is different bolt pattern

AND...the pinto BH i had rotated the gearbox a few degrees, would have needed a wedge under the tranny mount

                   ( one of Ford's better ideas, that they used up to heavy trucks)

Edited December 21, 2025 by 7Westfield

[Captain Tom]

Morning, the guy I got the 5 speed from has a close ratio 4 speed with an aluminum bell housing he wants to sell. Can put you in contact with him if anyone’s interested.  Tom

[EdWills]

On 11/29/2025 at 5:30 PM, Christopher smith said:

Does anyone know which  4 speed gearbox used in the series 2 Super 7 1500 Lotus sourced from? The input splines and diameter and output as well? The Pinto box I have has 1 inch 23 spline input and it was really tough finding a new 7.5 inch ( 190 mm clutch disc) and the pressure plate to fit  but maybe used in an early Mk1 Escort -UK only?- the Pinto took a larger one). The 7.5 set-up bolts up exactly to the 1500 GT flywheel and the bellhousing is a Cortina I think and has a right side starter and a large rectangular opening for an external slave cylinder on the left which I do not have and probably could not adapt to the Pinto box input anyway.

Hi CHristopher.

According to author Paul Davies who wrote a book for Cars and Car Conversions titled "Tuning Four Cylinder Fords" (published 1971), quote: 'First all-syncro box was that fitted to the 1200cc Anglia Super and the 1200 Mk 1 Cortina. Apart from the advantage of having a syncro first, this unit should be regarded in the same light as the 105E/109E boxes (my note - no syncro on first on these earlier boxes) having ratios unsuitable for spirited motoring. In this same form this box was also used in the 1500 Cortina, Classic and Corsair models, and - initially - in the GT versions with the addition of a remote change" (remote change part 113E).  He also notes: "Ford Performance Centre (as it was then) marketed a special kit which provided uprated 1st, 2nd and 3rd cogs for the 1500 GT casings." These were later incorporated into the 'new' (for 1967) box known 'incorrectly' (Mr. Davies' words) as the 2000E box (actual 2821E).  The 2821E was later fitment into some 1969 manufactured Lotus Seven Series 3 models as supplies of the 116E dried up, plus the Seven Series 4 and Elan. The Lotus Cortina Mk 1 received an ultra close ratio box which Mr. Davies noted proved a little unsuitable for everyday use.  In the Lotus Seven Owners Manual, Lotus refers to the 116E as an engine and gearbox combination.  Christopher, I mentioned to you once before about Burton Performance in the U.K.  I realize with the ongoing tariff situation that importing from the U.K. has become overly expensive, but Burton does have good reference material for clutch and gearbox combinations.  The 1 inch 23 spline you note was used with the 'Type E' Rocket Box' (single rail operation - as used on the European Ford Taunus and others?).  The original equipment gearboxes used the 7/8" x 20 hub  according to Burton.  I will attach a page from their old print-out regarding AP clutches (these original AP clutches may not be available now, but replacements are), which may help decipher the combinations. If you think it will be useful, a copy of the latest Burton catalogue may be very helpful to you, or just check on-line https://burtonpower.com   Only cost for the catalogue will be postage (no tariff charge). It details the full range of gearboxes produced for the U.K. and European markets with all the necessary accessories noted. I have also added a page from the Autopress Ltd Ford Cortina 1967/68 manual where I noted the parts required for my 116E box rebuild as fitted to my 1969 reg. (built in 1968) Series 3.  I am guessing that these parts have been unavailable for some time?. Cheers, W. 

[Christopher smith]

7 hours ago, Captain Tom said:

Morning, the guy I got the 5 speed from has a close ratio 4 speed with an aluminum bell housing he wants to sell. Can put you in contact with him if anyone’s interested.  Tom

Many thanks- yes, I am interested in learning more. I will need everything between the flywheel and the driveshaft yoke, assuming they have the same output shaft configuration. I will also need the entire slave cylinder + T.P. bearing and hardware and a shifter set-up or at least a sure place to source all those parts. Please let me know how to make contact and learn about history/condition.

[SENC]

The Dave Bean catalogues also have a good bit of information.  When I'm at the shop later this morning I'll see if I can grab a few pics from the English Racing Fords manual, my recollection is that it includes a detailed section on the various gearbox iterations.

 

[joe7]

PM sent.

[SENC]

[SENC]

And the clutch matrix from the same resource...

 

 

If you don't have a copy, it is worth getting - I think Dave Bean still offers copies.  If not and you want one, I think I may have a 2nd copy somewhere.

[Christopher smith]

28 minutes ago, SENC said:

And the clutch matrix from the same resource...

 

 

If you don't have a copy, it is worth getting - I think Dave Bean still offers copies.  If not and you want one, I think I may have a 2nd copy somewhere.

Thanks- looks like the same one I have

[joe7]

PM sent about early 7 transmissions

[MV8]

A ten inch wide opening at the front of the tunnel would make a T5 an option.

[MV8]

Has anyone tried fitting the roller follower ohc lima 2.3l or 2.5l in place of a kent? The engine height to the valve cover is nearly identical but the exhaust is on the right. Then the common '80s ranger Toyo koygo 5 speed could be used as it should be narrower/lower torque capacity than a T5. 0.84:1 5th and would bolt up. OEM hydraulic release bearing so no external slave or cable clutch.

 

An M50D-R1 from an '88 and newer lima ranger may fit but it would be wider/higher torque capacity. 0.79:1 5th.

[EdWills]

Just rechecked the Burton Power web site, and the 2025/26 catalogue is free with free delivery world-wide (Just ordered one.  I have no connection to this company, but have sourced many parts from them in the past).  A download version of the catalogue is available at https://burtonpower.com and on pages 114 and 115 there are colour photos of each Ford transmission with parts list and details of each.  W

[Christopher smith]

2 hours ago, EdWills said:

Just rechecked the Burton Power web site, and the 2025/26 catalogue is free with free delivery world-wide (Just ordered one.  I have no connection to this company, but have sourced many parts from them in the past).  A download version of the catalogue is available at https://burtonpower.com and on pages 114 and 115 there are colour photos of each Ford transmission with parts list and details of each.  W

Many thanks! Great info source. I can finally find out which gearbox, clutch and slave cylinder to go with.