Many things have been done since that last post!
I'll bombard this place with more photos and less words.. [Not sure why some of the photos have rotated in a different direction]
After cutting that bumper, I made a splitter for it:
![1.jpg](./download/file.php?id=8127&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![2.jpg](./download/file.php?id=8128&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![3.jpg](./download/file.php?id=8129&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Then acquired a set of DC side-skirts, which I repainted along with mi whale shark bumper:
![4.jpg](./download/file.php?id=8130&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![5.jpg](./download/file.php?id=8131&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Replaced my trailing arm bushes:
![6.jpg](./download/file.php?id=8132&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Took apart the foglight housing, to get rid of the disgusting plastic ridges inside. Sent them to a machining shop, who sanded them out, and also polished my intake. Here's a before and after:
![7.jpg](./download/file.php?id=8133&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![8.jpg](./download/file.php?id=8134&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![9.jpg](./download/file.php?id=8135&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![10.jpg](./download/file.php?id=8136&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![11.jpg](./download/file.php?id=8137&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![12.jpg](./download/file.php?id=8138&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Noice and shoiiinyyy.
Then got myself a set of Evo X BBS rims. Which had a really bad paint job on them. So decided to clean it up a little and get them powder coated. Then whacked a set of Michellin PS4's on them:
![13.jpg](./download/file.php?id=8139&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![14a.jpg](./download/file.php?id=8140&sid=bb1c7910b3d2583bfad542abb34fd22f)
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After that, I replaced all the brembo hardware; sliding pins and retaining springs:
![15.jpg](./download/file.php?id=8141&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Got her fully tuned, and installed a CF missile switch because I'm a ricer, which toggles my haltech map into low and high boost; low boost at 8psi for daily driving, and high boost at 16psi with some fueling, pops and flames for spirited driving.. because why not.
![16.jpg](./download/file.php?id=8142&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![17.jpg](./download/file.php?id=8143&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Having some fun with the car...
![18.jpg](./download/file.php?id=8144&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![20.jpg](./download/file.php?id=8146&sid=bb1c7910b3d2583bfad542abb34fd22f)
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And henlo here I am, happy with everything before it turns to sh*t.
![21.jpg](./download/file.php?id=8147&sid=bb1c7910b3d2583bfad542abb34fd22f)
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And yep, this happens, doing some 4th gear pulls at 100kmph on the freeway, I hear a massive bang from the gearbox, and find myself 5 neutrals. Had to coast to the emergency lane and get towed home.
![22.jpg](./download/file.php?id=8166&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Initially thought it was the clutch that had failed, since all the gears were going in fine but not engaging/not being able to move the car.
Replaced the clutch with an Exedy Heavy Duty Cushion Button Clutch MBK-6429HDCB which has a clamping load of 876kg and torque rating of 503Nm. Along with that, I replaced the Flywheel friction plate with the Fidanza 2290001:
![24.jpg](./download/file.php?id=8149&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![a.jpg](./download/file.php?id=8167&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![b.jpg](./download/file.php?id=8168&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![c.jpg](./download/file.php?id=8169&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![d.jpg](./download/file.php?id=8170&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![e.jpg](./download/file.php?id=8171&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Put the gearbox back in, and turns out I still couldn't properly move the car in any gear. So... took the gearbox out againnn, pulled it apart, and found this: A broken output shaft...
![25.jpg](./download/file.php?id=8150&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![26.jpg](./download/file.php?id=8151&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Bought all new seals, synchros, rings, hub sliders and an output shaft (MD747931, with MD770265 apparently being the newer revision)
![27.jpg](./download/file.php?id=8152&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![28.jpg](./download/file.php?id=8153&sid=bb1c7910b3d2583bfad542abb34fd22f)
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It is very subtle but it appears that the new shaft has a slight fillet at the step where my previous shaft had failed.
The following two pictures show the difference at this point; 90 degree step vs. fillet.
![28a.jpg](./download/file.php?id=8154&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![28b.jpg](./download/file.php?id=8155&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Anyway, rebuilt both input and output shafts with new components:
![29.jpg](./download/file.php?id=8156&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![30.jpg](./download/file.php?id=8157&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![31.jpg](./download/file.php?id=8158&sid=bb1c7910b3d2583bfad542abb34fd22f)
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The outer race of the outer bearing on the output shaft was totally stuck in the box. No point sending it to a shop because they struggle with it too. Instead, just grind it out. I struggled to press it out and made a small crack in the aluminium casing.
![32.jpg](./download/file.php?id=8159&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![33.jpg](./download/file.php?id=8160&sid=bb1c7910b3d2583bfad542abb34fd22f)
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![34.jpg](./download/file.php?id=8161&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Looked like that outer race had gone through some heat or even fused to the box slightly - maybe due to the vibrations when the output shaft snapped:
![35.jpg](./download/file.php?id=8162&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Ended up replacing the box with a CE Lancer box for peace of mind - ripped the internals out and replace it all with the FTO rebuilt internals:
![36.jpg](./download/file.php?id=8163&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Got some new mesh for el whale shark bumper, put in the clear foglight and installed a lightbar:
![37.jpg](./download/file.php?id=8164&sid=bb1c7910b3d2583bfad542abb34fd22f)
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Looks pretty deec. She's back on the road now, running well. Just need to bed in the clutch for a while, and replace the gearbox oil soon as the synchros start to wear in.
![38.jpg](./download/file.php?id=8172&sid=bb1c7910b3d2583bfad542abb34fd22f)
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I think i'll start repairing my old dstocks bumper, fibreglass and respray it again. Just has a cleaner look.. throwback to the time when my FTO looked much cleaner:
![39.jpg](./download/file.php?id=8173&sid=bb1c7910b3d2583bfad542abb34fd22f)
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