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So I've been having a good think about fitting a Zetec engine to my mk2 Cortina 1600GT and although this is still very much in the brain storming phase ( I haven't even decided if it'll happen yet!), I would like some info on gearboxes.
I understand that the Type 9 gearbox can and will fit but I also understand that the transmission tunnel may need modifying. This is something I want to avoid at all costs. Can anyone confirm if it does indeed need modifying?
If it does, is there another gearbox that could work in place of a type 9 gearbox that would fit without modification to the chassis and transmission tunnel?
Thanks in advance.
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Phil H
Posted a lot
Posts: 1,448
Club RR Member Number: 133
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Jul 26, 2018 10:40:19 GMT
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Jul 26, 2018 11:34:13 GMT
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Hi, The problem is not the size of the tunnel Vs gearbox, it's the fact that the cars gear lever hole is further forward. The GTs and lotus's had gearlever extension housings that bolted on inside the car once the 'box was in, there were a couple of aftermarket ones. You may have to find a three rail 'box known colloquially as a 2000e 'box but were also fitted in Mk2 GTs. There were uprated competition versions called 'rocket' and 'bullet' box's but they are like hens teeth and priced accordingly.
Colin
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Last Edit: Jul 26, 2018 11:41:33 GMT by colnerov
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Jul 26, 2018 17:57:00 GMT
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I too have a mk2 16GT series 1. It should have as standard a 2000E 3 rail gearbox. This doesn't have the bolt on gear lever extension like a mk1 GT, but instead has the gear stick in the tail housing and not out of the top of the box like the lesser powered Mk2s. The gear box tunnel on a series 1 is the same as a mk1 Cortina in that it has a dip in the tunnel (just before the gearstick hole). This bit needs to be cut and raised if fitting a type 9. The series 2 has a single rail gear box and the larger auto tunnel so the type 9 fits with no body mods.
The beauty of the 2000E box is that it has semi close ratios which are good fo acceleration unlike the type 9 where you can drive a bus between the gap of first and second. If you fit a type 9 and want to keep the standard cortina bell housing you need to buy a kit for a couple of hundred pounds to convert.
The general consensus in the mk2 owners club is the type 9 isn't worth the hassle so just fit a new 3.5:1 cwp for less than £300 if its better cruising your after
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Last Edit: Jul 26, 2018 17:58:00 GMT by jonsey
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Jul 27, 2018 10:36:56 GMT
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I too have a mk2 16GT series 1. It should have as standard a 2000E 3 rail gearbox. This doesn't have the bolt on gear lever extension like a mk1 GT, but instead has the gear stick in the tail housing and not out of the top of the box like the lesser powered Mk2s. The gear box tunnel on a series 1 is the same as a mk1 Cortina in that it has a dip in the tunnel (just before the gearstick hole). This bit needs to be cut and raised if fitting a type 9. The series 2 has a single rail gear box and the larger auto tunnel so the type 9 fits with no body mods. The beauty of the 2000E box is that it has semi close ratios which are good fo acceleration unlike the type 9 where you can drive a bus between the gap of first and second. If you fit a type 9 and want to keep the standard cortina bell housing you need to buy a kit for a couple of hundred pounds to convert. The general consensus in the mk2 owners club is the type 9 isn't worth the hassle so just fit a new 3.5:1 cwp for less than £300 if its better cruising your after Thanks for your input, it's much appreciated. My main concern was that if I had fitted a Zetec engine was that the gearbox wouldn't be man enough to cope with the power and I'd be sat at high RPMs whilst cruising on the motorway. |
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Jul 27, 2018 11:18:57 GMT
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If you really want a 5 speed I think RetroFord has developed a kit to fit the Mazda mx5 gearbox into a mk1 Cortina. I'm not sure if body mods are required and doubt very much it'll be cheap but his kit is usually spot on.
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Jul 27, 2018 11:20:35 GMT
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To be honest, I'd rather keep the gearbox it has but I just don't know whether it can handle 160-200bhp.
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Jul 27, 2018 11:26:44 GMT
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Here you go. Looks like you would have to cut out the tunnel x member but if you drill out the spot welds it's easily replaced if you decide to go back standard   |
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Jul 27, 2018 11:31:37 GMT
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Thanks for your help. Much appreciated.  I don't suppose you know of how much power the standard 1600GT (type 3?) gearbox can handle? Sorry for all the questions, I've never worked on a Ford of this vintage. |
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Jul 27, 2018 14:46:30 GMT
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Not sure, but the 2000e came as standard in a Mk1 Escort Mexico so is probably ok up to a fairly hot x flow. You can obviously uprate the box with a gear kit. You even used to be able to get a 5 speed gear kit for them but it would be straight cut and I think they are 1:1 5th gear so you no better off without going for a 3.5:1 diff. I think Retro Ford even do a 3.3:1 diff now for even lower cruising rpm
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Last Edit: Jul 27, 2018 14:49:11 GMT by jonsey
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Jul 27, 2018 17:04:27 GMT
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Hi, It's not so much the power that kills gearboxes but the torque. The Kent crossflow back in the day could be tuned to 130 bhp so similar to a standard zetec. The gearboxes were used behind the Essex 3 litre V6 in the Savage conversions and they were 138 bhp and 183 ft/lbs of torque and used to cope with that OK. Ford had at that time had a reputation for good gearboxes. So I would say you don't have much to worry about.
Colin
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Last Edit: Jul 27, 2018 19:02:28 GMT by colnerov
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scimjim
Club Retro Rides Member
Posts: 1,503
Club RR Member Number: 8
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Jul 27, 2018 18:36:08 GMT
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I’m surprised the Savage used the 2000E box as the the type 5 was available, the same dimensions, stronger, etc - and used in the Scimitar?
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Jul 27, 2018 19:48:42 GMT
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Hi, It's not so much the power that kills gearboxes but the torque. The Kent crossflow back in the day could be tuned to 130 bhp so similar to a standard zetec. The gearboxes were used behind the Essex 3 litre V6 in the Savage conversions and they were 138 bhp and 183 ft/lbs of torque and used to cope with that OK. Ford had at that time had a reputation for good gearboxes. So I would say you don't have much to worry about. Colin Thanks for your input. That's a reasonable amount of torque! Likely more than could be achieved from a Zetec with throttle bodies. It's certainly given me some thinking to do. |
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Jul 27, 2018 20:21:39 GMT
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I’m surprised the Savage used the 2000E box as the the type 5 was available, the same dimensions, stronger, etc - and used in the Scimitar? I think the pre-1972 V6 boxes left a lot to be desired on the ratio front, the Mk1 Granada and post-'72 Capri were a vast improvement. The only V6 box available when the Savage was built would have been the earlier Mk4 Zody unit |
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1953 Minor (Long term project)
PT Cruiser
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Jul 27, 2018 21:59:35 GMT
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I’m surprised the Savage used the 2000E box as the the type 5 was available, the same dimensions, stronger, etc - and used in the Scimitar? I think the pre-1972 V6 boxes left a lot to be desired on the ratio front, the Mk1 Granada and post-'72 Capri were a vast improvement. The only V6 box available when the Savage was built would have been the earlier Mk4 Zody unit Hi, That's right, they were a bulky 'box and the change was considered slow because of the external linkage. Colin |
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Jul 27, 2018 22:22:11 GMT
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You can get a adaptor plate for around £100 which mates a rx8 5 or 6 speed to the zetec, gearstick comes out in same place as late mk 2 cortinas. We are planning to use this on a 100e project but the tunnel has already been modified.
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Ritchie
Club Retro Rides Member
Posts: 770 
Club RR Member Number: 12
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If you do decide to go with the Mazda option, be careful who you buy the adaptor plate from.
There is a guy who goes by the name p9cyo on the Turbosport forum, his website is here -
p9cyoplates.co.uk
He ripped me off and multiple others.
There is another guy on the Turbosport forum doing them, I can pass on his email if you like.
I got one from him with no problems.
I do think there are a few people doing them now, as mentioned, Retroford being one.
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Jul 28, 2018 10:56:28 GMT
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If you do decide to go with the Mazda option, be careful who you buy the adaptor plate from. There is a guy who goes by the name p9cyo on the Turbosport forum, his website is here - p9cyoplates.co.uk He ripped me off and multiple others. There is another guy on the Turbosport forum doing them, I can pass on his email if you like. I got one from him with no problems. I do think there are a few people doing them now, as mentioned, Retroford being one. Thanks for the heads up. I've been victim to some scrote on a Saab website. Took my money and ran! I think I'll stick with the standard gearbox and have it rebuilt if it can't handle the torque from a zetec lump. Next question is, just how easy is it to mate the zetec to the standard gearbox? |
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Jul 28, 2018 13:10:31 GMT
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The bell housing will bolt straight up. The zetec fly wheel should fit easily in the bell housing too judging by the 2 gearboxes I have 1st type9, 2nd 2000e   I'm thinking you'll probably have to use the zetec clutch cover and Cortina plate but have no idea if this is correct. You'll also have to try different release bearings to get the spacing right but none of this is rocket science. If you go on the mk2 Cortina owner club fb page, there is a guy on there called Nigel Eaton who does a lot of zetec conversions. He should answer all your questions |
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Last Edit: Jul 30, 2018 15:11:53 GMT by jonsey: As pictures can out in wrong order
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Jul 28, 2018 21:02:37 GMT
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Very kind of you, Jonsey. I've joined the Facebook group so will send him a message tomorrow morning.
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