[quote=ade]Speak to John at JSR, you need the Jubu racing semi helical gearset and JSR will do you the bespoke gear oil cooler like mine, the downside is the oil pump and gearset took a month or so to get due to long order times.
I put in a 2nd hand celica gearbox for �300 to last me till the new one was completed.
Mine made a terible noise when it went as well, but I still drove it home from Spa. 
Did it sound like this?
Exige Gearbox Failure - YouTube
[/quote]
Yes exacty like that. Will investigate the JUBU racing Gears.
Thanks
Ex77
Get the gearset from them here Jubu
And talk to John at JS Racing for info for fitting etc.
[quote=ade]Get the gearset from them here Jubu
And talk to John at JS Racing for info for fitting etc. [/quote]
I’m not convinced thats a fix though…
�700 for the gears, gearbox recondition and custom oil cooler will cost a fair bit and still doesn’t address the weak syncros. Surely cheaper and much better fix is to try sn develop the Audi 6speed box? Just need someone with the skills prepared to give it a go…
Hangar 111 built my box up with the jubu gears and final drive. They have done several more for other customers since. If it’s a road car beware the final drive as it is straight cut and hence noisy.
Good point that about the gears being straight cut! I want a car that I can drive to and from the track, but also be useable for weekend trips with the missis - The whine of 3rd and 4th gear would probably drive her, and ultimately me mad.
Good point that about the gears being straight cut! I want a car that I can drive to and from the track, but also be useable for weekend trips with the missis - The whine of 3rd and 4th gear would probably drive her, and ultimately me mad. [/quote]
If you just go for 3rd and 4th then its fine as they are semi helical and not significantly noisier. Its only the final drive that’s straight cut, and it is significantly noiser.
Just re read the thread. As far as the failures on the std car are concerned then if its Walshy then its hardly had a sheltered life. Re the synchros, I know these are a weak point but they shouldn’t be subject to additional load after a power upgrade unless I’m missing something and I was supposed to be flat shifting
Using a level of mechanical sympathy whilst driving will sort the syncro issue, that is not HP related as Will says, the gears are the weak link for high HP. The semi helical cut gears I have you can barely hear over the SC whine and to be honest if you do hear it it just sounds cool to have a little straight cut gear noise 
The oil cooler system was not in the end that expensive as the pump and laminova together were only a few hundred, most of my costs were for one off costs for designing and making brackets custom fuse boxes and wiring, don’t just dismiss as too expensive when nobody has actualy asked John to price one up. I’m sure subsequent ones will be cheaper and if you factor in a LSD and Clutch change and flywheel at the same time the gearbox removal/rebuild cost is not bad at all.
Oh forgot to add you can only hear the gears in 3rd and 4th noy at all the rest of the time
[quote=ade]Using a level of mechanical sympathy whilst driving will sort the syncro issue, that is not HP related as Will says, the gears are the weak link for high HP. The semi helical cut gears I have you can barely hear over the SC whine and to be honest if you do hear it it just sounds cool to have a little straight cut gear noise
The oil cooler system was not in the end that expensive as the pump and laminova together were only a few hundred, most of my costs were for one off costs for designing and making brackets custom fuse boxes and wiring, don’t just dismiss as too expensive when nobody has actualy asked John to price one up. I’m sure subsequent ones will be cheaper and if you factor in a LSD and Clutch change and flywheel at the same time the gearbox removal/rebuild cost is not bad at all.
[/quote]
Quite right, which is exactly why I have always heal and toe�d and more recently double clutch every down change. Syncros issues are not power related, but numerous cars ruining 2-3 syncro � they are literally made of cheese! I just think the gearbox as a whole is far too weak, not just the 3rd gear. Admittedly mine has lasted, and my car was one of the first 300bhp cars (converted early 2008) and has covered probably 20k road/track miles at 300bhp, but I don�t expect it to last.
The modifications done to your gearbox would probably cost around �1,500, and that�s not including removal and installation. I�m reluctant to spend that of money to not completely overcome the gearbox issues. I�ve held of buying an uprated clutch too as that will costs another �500 on top of the gearbox, when the only real solution is to change the gearbox - An off the shelf audi/vx clutch would probably be more than up for the job, and 2/5th of the trd clutch so there are savings there.
Again speak to John at JS Racing about the Audi option, if I had not already put a load of cash into mine it was our next option, the good points of it are that it is easy to do the gear linkage and driveshafts as this is already done, downside is the bellhousing, clutch and starter issues.
Fianally cost might be a problem if you are the first 
As for the toyota clutch �500 is just too much you want to only pay �350 tops for one get a torsen LSD 2nd hand like I did for �250. I had to spend a lot more as I had to buy a gearbox 2nd hand that was good as mine was ruined, I bet the price won’t be as bad as you think
[quote=ade]Again speak to John at JS Racing about the Audi option, if I had not already put a load of cash into mine it was our next option, the good points of it are that it is easy to do the gear linkage and driveshafts as this is already done, downside is the bellhousing, clutch and starter issues.
Fianally cost might be a problem if you are the first
As for the toyota clutch �500 is just too much you want to only pay �350 tops for one get a torsen LSD 2nd hand like I did for �250. I had to spend a lot more as I had to buy a gearbox 2nd hand that was good as mine was ruined, I bet the price won’t be as bad as you think [/quote]
Already got the standard loti lsd
I do need to price the options up…I want to be able to run safely more than 300bhp next year 
Just to put some figures around all of this.
Remove and refit gearbox to an NA car is 8 hours and an SC car is 10 hours, this includes checking the clutch condition.
We charge �45 per hour + vat
To strip and rebuild the gearbox with a Jubu gearkit and install an LSD is �350 + vat
The Jubu gearkit is �680 + vat
Quaife ATB LSD is �585 + vat
Diff bearings (sometimes required depending if the original ones will pull off the original diff OK) �60 + vat
An new uprated Helix clutch, these really are the nuts and will easily handle more power than a supercharged Toyota will give you is �350 + vat (that is the clutch cover, the friction plate and a new release bearing)
The gearbox cooler including, pump, laminova, all pipework, fittings, wireing, redline gearbox oil and anti freeze is �820 + vat fully fitted.
The Audi gearboxes really are very strong. I run the 02J 5 speed box with 430bhp and 360lbft torque and have never broke a gear. The 6 speed gearbox is even stronger.
We have talked this conversion over and drawn up the requirements for the conversion. It is not a 5 minute job to get one bolted to the side of a Toyota engine and will require a one off flywheel, different driveshafts, modification to the gear linkage, three new engine mounts (three of the mounts in a toyota Lotus are bolted to the gearbox), adaptor plate to physically make it bolt onto the engine etc etc etc, so at the end of the day its not going to be super cheap.
You wont need a cooler though as the audi boxes simply dont get hot (we have been data logging the temps for three years)
We believe we can have this conversion fitted into a car for �4,000 + vat. That is drive in drive out, fully fitted. That would include complete new drive shafts, new engine mounts, new clutch and flywheel, modified linkage etc etc etc.
We basically just need the first person to put their money where their broken standard gearbox is.
Oh by the way the geabox ratios in the Audi 6 speed are very very nice and amply close enough. You would infact get a choice as there are 4 different varients.
Oh an LSD would be extra and cost about the same for an Audi box as they do for the Toyota box.
I have a Helix clutch in mine , proving very good for me at the moment…
Also have the quaife , their reputation is second to none…
I’ve killed three Toyota gearboxes, they are made of cheese… The box is designed for a peak torque of 178 ft tq in a front wheel drive configuration. The rear/mid engine setup of the Lotus puts loads on to the gearbox beyond its original design…add power and the box will fail…just a matter of when.
If SeanB can get the Audi box configured for the 2ZZ then a real solution will be available at reasonable price…
You could always go my route and use a modified E153 but it is better suited for mental power due to it’s taller gearing…
[quote=ade]Speak to John at JSR, you need the Jubu racing semi helical gearset and JSR will do you the bespoke gear oil cooler like mine, the downside is the oil pump and gearset took a month or so to get due to long order times.
I put in a 2nd hand celica gearbox for �300 to last me till the new one was completed.
Mine made a terible noise when it went as well, but I still drove it home from Spa.
Did it sound like this?
Exige Gearbox Failure - YouTube
[/quote]
Hi Ade
A little help please, do you know if the linkage had to modified for the Celica box to fit as I believe its on opposite sides from celica to Exige.
Thanks
[quote=SeanB]
We believe we can have this conversion fitted into a car for �4,000 + vat. That is drive in drive out, fully fitted. That would include complete new drive shafts, new engine mounts, new clutch and flywheel, modified linkage etc etc etc. [/quote]
hhmmm for �4k for the audi box and fitting it almost makes sense to wait and do the thing properly…'box and engine for circa �10k then you’ve got a better platform for 400+bhp should you want to still keep tuning it (which you will). You’d probably be able to sell on your old tuned yota lump for a couple of thou too. This is probably the route I’ll go.
[quote=Whiteysback][quote=SeanB]
We believe we can have this conversion fitted into a car for �4,000 + vat. That is drive in drive out, fully fitted. That would include complete new drive shafts, new engine mounts, new clutch and flywheel, modified linkage etc etc etc. [/quote]
hhmmm for �4k for the audi box and fitting it almost makes sense to wait and do the thing properly…'box and engine for circa �10k then you’ve got a better platform for 400+bhp should you want to still keep tuning it (which you will). You’d probably be able to sell on your old tuned yota lump for a couple of thou too. This is probably the route I’ll go. [/quote]
I really admire your commitment to modding your car but how and when did you decide to chuck 2 years warranty out the window ?? 
Lol…this is my 2nd exige and after leaving my 1st one standard I swore if I got another I’d get running exactly how I’ve always wanted it too. Plus tuning is just too addictive, it starts with uprated wiper blades and before u know it you done a bundle on everything else!
Personally I blame Ade, Nieves, Frank and everyone else on exiges.com!
Hey I didn’t do it, it was a guy that looks just like me…yeah that’s the ticket… 
I think I may have answered my own question but confirmation would be good.
My understanding is that celica gearbox has the same linkage as the Lotus, and on the corolla box the it comes out the opposite side?