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  1. petert

    ML5 Installation

    I’ve searched, but I can’t find any conclusive, concise guide for fitting an ML5 into a 205. I’m keen to build a more reliable drivetrain for my turbo project, than a BE3. I purchased the ML5 that Calvinhorse was selling: https://www.205gtidrivers.com/forums/topic/175137-for-sale-weird-ml5-box-with-be-bellhousing/?tab=comments#comment-1537822 For two reasons. One, it has a 4.54 cwp (lower than most ML5 boxes). Two, it has a cable clutch. All the boxes in Australia are hydraulic. It seems only the 806 RHD had a cable clutch. The basic plan is to combine a V6 set of gears with the 4.54 cwp. That should yield about 230km/h @ 7000. Clutch Operation The cable clutch was appealing for ease of installation, but I can see that a 500Nm clutch could be an issue. It may well have to be a Saab type direct hydraulic conversion. I can deal with this if need be. Linkages: The ML5 levers move in a plane approx. 70º to the driveline axis. So adapting the Sachshift is an issue. Perhaps 406 type cables & gear stick are the only alternative? Does anyone know? Dimensions: The ML5 is approx. 400mm long. Thus longer than a BE3 but shorter than a BE3/6. It should finish flush with the inner wheel arch. The radius is an issue however. I’m guessing 25mm more than a BE3? Thus modification of the cross member will be required, for cwp cover clearance. Driveshafts: I’ve secured a pair of 406 ML5 driveshafts, from which I can use the inner CVs and hopefully the shafts themselves. I’m told the outer CVs could still be an issue. I’ve also secured a 406 ML5 bottom engine mount, which supports the larger bearing of the long driveshaft. Flywheel/Clutch: This will still be a 184mm TTV flywheel and twin plate clutch. I’ll need to buy two clutch plates and throw out bearing to suit the ML5 spline. Diff: I’ll have to buy an LSD. Probably a 3J? What have I over looked or miscalculated?
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