Most liked posts in thread: The Phoenix - The GP Roadster Project

Aisin auto transmission, separated from the engine and ready to be torn down into a zillion pieces.

 

So to catch up a bit:

* I rebuilt the tranny. It kinda sorta works. But not really. So I'm punting and doing a manual conversion.
* After reinstalling everything, the engine started on the FIRST TRY. That was a fantastic feeling. I didn't miss anything.
* Even though the tranny is crap, the engine is running fantastically. I've been flogging it in third gear.
* My top isn't working. Discovered this several months ago. I'm going to dig into it this weekend.

I'll state the obvious. If you are thinking about transmogrifying your MCS automatic into a manual, you are most likely INSANE. Certifiable. Seek help. Seriously. The only rational way to do this, is to sell your car, and buy a different car with the right transmission.

If you are still reading, then you're INSANE. But you may be in a position like me, where you are pathologically and incurably addicted to a very specific MINI, or you've invested in making your Mini one-of-a-kind, and it's just not practical to either sell it, or start over from scratch. So, onward with the conversion.

First, if you're planning to do an MCS auto-to-manual conversion, good luck finding info. The Justacooper CVT-to-manual conversion is a pretty well known process. But the MCS is a different beast. Because the Aisin is much fatter than the CVT or the manual 6 speed, Mini shifted the engine over to the right about 5/8" (if memory serves). And that meant replacing a lot of parts.

You can fire up RealOEM for your car, and then browse all the categories to see where different parts are listed for the Automatic. They include (not a complete list):
* Clutch and all related hardware and hydraulics.
* brake and clutch pedal assembly
* shifter assembly and cables
* both axles
* engine and transmission mounts
* supercharger inlet duct
* throttle mounting bracket
* brake booster vacuum line
* fuel tank breather line
* main air intake hose
* plastic airbox snorkel
* heater / heat exchanger hose assembly and various related parts
* engine oil heat exchanger and related hard lines
* radiator coolant hoses
* lots of related hardware
* ECU coding

While you could certainly figure out all the parts and buy them new, it really isn't cost-effective. The most rational way to do this very irrational thing, is to buy a parts car. Then you can park them side-by-side and move stuff over as needed to make it work. You might even consider moving an entire engine-and-transmission from the donor car to your car, if you happen to find a good one with significantly fewer miles on it.

So that's what I'm doing - getting a donor car. At a minimum, I recommend installing a new clutch while you're at it, along with new seals. And replace the bushings, etc. on the clutch control assembly. And a new slave cylinder.

If I'm successful, this will actually be less expensive than buying a remanufactured automatic transmission and torque converter. But will be covering some uncharted territory, so there will be some figuring-it-out to be done. YOLO.

More to come as this unfolds.

 

By the way... the GP only had 76k miles on it, half as many as Blimey. So, if all is well with the GP engine, it's going in my car. I'll swap in my RMW cam and get a fresh tune. Keep my old engine (which is still strong) as a spare or future "built" engine core.

 

Gawd, I hope so. :confused5:

I just told my driving gang, "you do realize, I'm going to have like three weeks to re-learn how to shift manual, with anger, before MOTD?"

I'm going to be shifting like a teenager in a Ferrari. It's gonna be pretty ugly for a while, I'm afraid.

I've driven friends' MINIs and Lotuses and stuff A LITTLE in the past few years. But it's been 30 years since I've driven manual more than occasionally.

Last manual I owned: My 1977 TR7. Sold in 1986.
At least, since then, I've learned that slipping the clutch isn't a good thing.

 

That would have probably worked. But so did charging the battery. It's been open for 2 days now.
And catch is off, so will never be a problem again.

 

Joked with the wife that I could probably fit three MINIs in this garage, on dollies like this.

She was not amused.

 

Spent most of the day unraveling eight years worth of electrical mods. Lots is stuff I don't need anymore was inhabiting the space under my dash, my cowls, my engine bay, my bonnet, and anywhere else I could shove something...

Much better now. Did manage to finish getting the EWS unit swapped, and got the pedals out while I was under there.

It's mostly about this, really.


Finally got Blimey jacked up and started tearing into the front end. Shed the bumper and wheel wells, intake, IC, and most of the engine harness. Unbolted header and drained coolant. Should be able to get the engine out tomorrow.

 

1) the GP has special software beyond straight JCW software. Only available on GP ECU's. Even if you're getting a custom tune on top of this, the GP software is the best 1st gen Mini foundation to start from.
2) the GP engine has half the miles of my old engine
3) the GP engine has a JCW head on it. Which I'll eventually upgrade to a BVH
4) this is now as much about saving the "soul" of GP0769 as anything else. Think of it as doing a "chassis swap" on 0769, more than just doing an "engine swap" on Blimey

 

Cleaner...


Masked and primed...


Maybe the only cabrio with a Thunder Blue engine bay?

 

Lots of progress today!

Started with this:


Took a detour for a few hours, to pull the A-panels and cowls off both cars.

Then, after a few hours, got back to this:


Engine bay reassembled, heat shields and exhaust reinstalled, GP cowl fitted.


Driver's side of my cowl got banged up in the tire wall incident. The paint on this one needs refreshing, but it's dent-free. And GP-colored!

For those of you who haven't swapped the cowl on a MINI... it's a biotch.

Clutch arrived. Guaranteed to fail, or your money back! But I don't expect it to be a long-term solution, and this isn't a daily driver anymore, so it won't see a lot of miles. And, who knows... maybe they've figured out how to make them more reliable, after all the failures a few years back. We'll see.


Installed clutch, fitted transmission to engine, and started installing other stuff (rear coolant lines, starter). Drained the rest of the fluids. Ready to install back in the car tomorrow!



My buddy Wellzy is driving down from Ohio tonight, to help me get it buttoned up over the next couple of days. I may be driving on Saturday!