Freelander 1 Freelander 1 PG1 gearbox problem

Freelander Winnie said:

Thanks for this link, I've just had a read and asked a question. They used the PG1 gearbox and I think the MG ZT-T clutch assembly (somehow).

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The PG1 box as different bell housing sides of its casing to suit whatever engine is mated too. The PG1 from a M or T series engine won't mate to a 1.8 K series. The IRD is also fitted to the bell housing side if the casing. As no other vehicle in the Rover range had an IRD, the bell housing side of the casings aren't made to fit the IRD. This is why your box choices are limited to FL1 only boxes.

rob_bell said:

You can upgrade the standard PG1 by replacing the plastic caged bearings with steel replacements- will be doing something similar later this year

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That's only part of the upgrade. The standard "high torque" box has doubled main shafe bearing to keep the gears in alignment under torque.

rob_bell said:

It’ll be up-rated with steel caged bearings as all turbo PG1 boxes (petrol or diesel) are

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You'll need to machine the box to take the double main shaft bearings too.

To go the whole way, yes, I’m sure you’re right Nodge, but you can build a pretty resilient box by upgraded the existing bearings - but this is not based on personal experience (yet!)

When researching gear ratios and gearbox codes, I wrote this which may be helpful: http://www.mgf.ultimatemg.com/group1/info/Gearbox_numbers/index.htm

The gearbox castings are unique to Freelander, but I suspect the internals are largely “standard” PG1*

* this is a guess, but knowing Rover, I’d be surprised if it weren’t the case!

rob_bell said:

To go the whole way, yes, I’m sure you’re right Nodge, but you can build a pretty resilient box by upgraded the existing bearings - but this is not based on personal experience (yet!)

When researching gear ratios and gearbox codes, I wrote this which may be helpful: http://www.mgf.ultimatemg.com/group1/info/Gearbox_numbers/index.htm

The gearbox castings are unique to Freelander, but I suspect the internals are largely “standard” PG1*

* this is a guess, but knowing Rover, I’d be surprised if it weren’t the case!

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Actually the standard 1.8 K series box will take the torque of the turbo engine for a good while before it fails. It's a trade off between cost of making the box last, vs the cost of simply replacing it when it fails.

A 200 BHP 1.8 K series turbo will make around 180 Ftlb of torque, which isn't going to blow the box if care is taken. The IRD is more likely to fail if abused than the box.

Disco Mikey did lots of miles in his K series turbo on the standard 1.8 K series box. iirc.