I can insure a Mazda 3 MPS ( 2.3L 260BHP ) for 1000 euros.

Must be down to how rare the car is and thinking about parts if something was to go wrong. Still alot cheaper than UK - (I'm 23 Years old btw ), 2 Years no claims.. Insurance for the 1.6 8v astra was £2000 if i lived at my old address haha

I'd buy a Mazda 3 :laugh:

Yea i was looking at them but they go for 8000 euros compared to 4k RHD ...

Rather have the ZS tbh :)

Great way to 1. overheat the brakes and 2. have melted plastic on your car lmao!

Found cheaper insurance - 1050 euros from linea direct ( Direct Line )

Happy days!

They are OK, just when I had their renewal price it was £100 odd more that the cheapest one on Go Compare.

When I queried it they said it was a new customer discount, first time you go with them????

First time with this company. I'm with a company called balumba for 2 years and they quote 1500 euros so i'm going to call them and ask for a better price seems i've been with them for 2 years.... Lets see

Good luck, think they are starting to price match, over here.

;););)

Got my new clutch last night so i'm going to install it tonight if i can be bothered but before that. Does anyone know the Torque for the flywheel nuts?

Still waiting for my haynes manual to arrive.

Thanks!

Flywheel to crank bolts ?. 80Nm if so.

Right so i'm trying to align the clutch.I have the gearbox shaft from the old gearbox which i can use to align the clutch.

Why will it not slot in ? Seems i would need to use a hammer and alot of force just to get the shaft in. Is this normal?

No, is the old input shaft straight, or does it have any burrs on the end, it should just slide in, maybe you've found the reason the old gearbox had been taken apart.

Looks okay to the eye , first 4-5mm goes in and then it gets stuck.

I've used a socket for now and seems to be straight enough but the gearbox should arrive tomorrow so i'll see then.

Jumped into the car and pressed the clutch down by accident.

Now clutch slave cylinder now looks like this.

http://i33.photobucket.com/albums/d1...ps52f0ffb9.jpg

http://i33.photobucket.com/albums/d1...psba55b0c4.jpg

Can it be saved ? if so does anyone know how the hell it goes together.

Yep, it can be saved.

You will need to separate the pipe joint and remove the slave, then fill it with brake fluid, drop the spring in and then the piston with the seals at the top of the cylinder, while trying to push the piston in you'll need a second pair of hands to unseat the valve in the pipe, then put the push rod into place and the rubber dust seal, and then to prevent the piston popping out use zip ties or a g clamp, be warned it is a ball ache of a job.

Just a thought, is there any fluid left in the system ?.

Yea, some spilled out when it pop'd out but i can see the fluid in the bottom of the cylinder.

if you take the cap off the master cylinder is there fluid in the reservoir.

I'll take alook tomorrow as its under the fuse box.

If i have the pedal at the top then i see brake fluid in the slave and when its pushed down i see more fluid so i'm going to say yes there is a good amount of fluid in there

As ever a very good thread with some excellent advice and technical know how. Enjoying this one lots.

ive got a clutch system for sale if you need one

So the bottles half full with fluid.

How am i going to put it back together without getting air into the system?

You aren't going to be able to put it together without getting air in it, you will need to attempt to bleed it after re assembly, as I said the job is a pita.

As you still have fluid in the master cylinder I would fill the slave with enough fluid to refit the piston and rod without needing to compress the fluid, then operate the piston by hand to dislodge the air, any air should end up escaping from the system via the master cylinder.

Got the gearbox this evening.

Bloody hard work getting just under 40 kg to sit proper by myself.

Am i total bell end or is the wrong gearbox? Various holes lead to nothing as seen in the pictures and also doesnt look like it matches up.

http://i33.photobucket.com/albums/d1...psb1958bba.jpg
http://i33.photobucket.com/albums/d1...ps9a715102.jpg
http://i33.photobucket.com/albums/d1...ps7f5e42b5.jpg

That's definitely a pg1 box, what car did it come off ?.

2001 Zs 180 . Got kv6 marked on it

Now - I'm far from a guru, but, didn't your engine come from a 75 ? Don't they use a getrag gearbox ? Are they different ?

Good point.

Holy shoite - have I just got something mechanical in the right ball park ... ?

You have.

Well, the zt and zs block castings are the same, so the pg1 box should fit.

It does fit .. Just doesn't look correct. :/

Well done that man ! Has he gone and bought the wrong box then?

Got your pm and I'm at home for a bit this morning. I'll get some pics up.

Thanks Dan.

I looked at the block which came with the car , looks the same mounting points but ill double check last night as i couldn't see much at night.

Block castings are the same. They use different gearboxes yes, but they also use different mounting holes. You have to remove the dowels from the engine and line them up with the gearbox ones. From the pics it looks like the dowels are clashing.

Shall take alook tonight.

Thanks bud

So as Zred said , the dowels need to be removed and placed correctly. What i've read its not going to be an easy job getting them out without destroying them :/

Differences:
http://i33.photobucket.com/albums/d1...psbf50c631.jpg
Dowels are level with each other:
http://i33.photobucket.com/albums/d1...ps049d2bda.jpg

Also i need some seals for the driveshafts, are these the ones to get?
http://cgi.ebay.co.uk/ws/eBayISAPI.d...:X:RTQ:GB:1123

I think these are the same as the ones you linked to
http://www.ebay.co.uk/itm/MGZS-MG-ZS...item4607b3f5b5

Number 25 for new dowels http://www.rimmerbros.co.uk/Item--i-GRID003326