wraydon
Newbie
Donor : 2003 MK2.5 Six Speed
Posts: 8
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Post by wraydon on May 26, 2016 15:51:47 GMT
My brother and I purchased a donor car some time ago and have finally got round to stripping it down. The donor is a 2003 Mk2.5 with a six speed gearbox that has done 57,000 miles. It was a Cat C write off. It is going to be our first build and one of the reasons we chose this kit was this forum. So we need to thank you all already. One of the bits of advice we have taken note of is LABEL EVERYTHING
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Post by gwnwar on May 26, 2016 16:10:49 GMT
Labeling is needed.. But you need to label all electric connectors on both sides. Red flag all grounds.. One note with the 6 speed if you drain refill the trans make sure you pull the right fill plug..There is one that looks like a fill but is a blind plug for the reverse gear remove it and you will be tearing the trans apart to get bits back in place.. Wiring and other info here.. www.mellens.net/mazda/If you are not a member join www.miata.net/ lots of good info there..
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wraydon
Newbie
Donor : 2003 MK2.5 Six Speed
Posts: 8
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Post by wraydon on May 26, 2016 16:53:10 GMT
This forum has already been extremely useful and I have a feeling you have just saved us with the tip about the plug. Thanks again, all tips welcome and I'll check out those links
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Post by john on May 26, 2016 23:22:49 GMT
Hello and welcome, enjoy the process stripping down is very therapeutic.
Look forward to seeing a later mx5 being used as a donor. Mines a 99 mk2 but to see what's needed for a 2.5 donor will do the forum good.
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Post by R2S on May 27, 2016 7:18:56 GMT
Hello and welcome, enjoy the process stripping down is very therapeutic. Guys not sure I found the strip down therapeutic, had I had a swear jar in the workshop it would have made me a fortune. However on the up side the strip down did give a detailed insight into how everything works so rebuilding is very straight forward (albeit I haven't touched anything electrical wiring wise yet and the closer I get the more daunting it becomes - not helped by my donor having an alarm and immobiliser fitted).
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Post by gwnwar on May 27, 2016 17:59:26 GMT
Don't let the wiring get to you.. If all electric units work now problem will be connectors not made or grounds not made.. Get the car built and running less body on have all lights hooked up then you can start cutting wires if you want.. With a full body you can hide the wires neatly and not cut any.. Label all connectors both sides of connectors with tags not tape as it might come off. If things start going bad walk away come back later.. On any rusted nuts bolts spray and wire brush threads and use 6 point sockets so not to round off the heads.. Save all nuts bolts might need them.. Make up 4 8" wood 2x4 or tubing to stick between lower shock mount and upper control arms inner mount place.. That way the subs will not be on the ground and you can move the skate around. If you are going to be pulling the control arms off to blast and paint loosen the 4 center axle nuts while you still have brakes and E brake. Nuts are staked in place and will need long pipe as leverage to loosen.. Think ahead, be smart, stay safe, have fun.. Print off the wiring diagram for car put in plastic sleeves to use later. Ask questions it is not a sign of ignorance it is the smart thing to do..
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Deleted
Deleted Member
Posts: 0
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Post by Deleted on May 28, 2016 7:50:35 GMT
My Westfield build was with a mk2.5 but with the 5 speed box. Do you have the VVT engine?
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wraydon
Newbie
Donor : 2003 MK2.5 Six Speed
Posts: 8
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Post by wraydon on May 28, 2016 12:19:50 GMT
Yes. We have the VVT engine.
The engine runs very nicely so not planning to do much other than the 60k service - timing belt, oil, etc
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Post by gwnwar on May 28, 2016 20:25:14 GMT
This might help with the TB change.. forum.miata.net/vb/showthread.php?t=173584The VVT engine is not same as non VVT.. Also mark the top of both the cam gears and count belt tits between marks. Lock cams in place and paint marked with 2 wrenches and vice grips/c clamp before removing belt. Intake cam likes to slip over 1 or 2 teeth if not held in place.. Does your car only have 57000 KM that is only @ 35000 miles it should not need a TB of WP. Mazda says 60M Fed car>100M miles Cail. car in USA unless seals are leaking.. I would change the clutch unit and slave cly.
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Deleted
Deleted Member
Posts: 0
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Post by Deleted on May 29, 2016 5:39:18 GMT
The VVT is a sweet engine and makes your car a little different. On mine I did clutch, Belts and usual service items. Easy to do when the engine is out and you know it is good to go afterwards. A good way to do the TB is get a sharp knife and split the belt down the centre, remove half and slip the new belt on then cut the remaining half of the belt off. One thing to be aware of is the VVT is a taller engine because of the timing gear situated on top of the cam cover. On the Westy I had to fit an air scoop to clear the engine top, the Replicar has more adjustment in body height but keep checking that the bonnet closes. You also have some work to do on the headlight electrics, when you are ready for it I have a list of differences between mk1 and mk2.5 donors that I made for the Westy, not all will apply to the Replicar but some will and you may as well benefit from my experiences.
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wraydon
Newbie
Donor : 2003 MK2.5 Six Speed
Posts: 8
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Post by wraydon on May 31, 2016 9:53:47 GMT
This might help with the TB change.. forum.miata.net/vb/showthread.php?t=173584The VVT engine is not same as non VVT.. Also mark the top of both the cam gears and count belt tits between marks. Lock cams in place and paint marked with 2 wrenches and vice grips/c clamp before removing belt. Intake cam likes to slip over 1 or 2 teeth if not held in place.. Does your car only have 57000 KM that is only @ 35000 miles it should not need a TB of WP. Mazda says 60M Fed car>100M miles Cail. car in USA unless seals are leaking.. I would change the clutch unit and slave cly. It is 57,000 miles so will be doing the 60,000 mile service schedule + plus probably other bits as we don't know the past service history. Clutch will be replaced, silly not to really.
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wraydon
Newbie
Donor : 2003 MK2.5 Six Speed
Posts: 8
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Post by wraydon on May 31, 2016 9:57:13 GMT
The VVT is a sweet engine and makes your car a little different. On mine I did clutch, Belts and usual service items. Easy to do when the engine is out and you know it is good to go afterwards. A good way to do the TB is get a sharp knife and split the belt down the centre, remove half and slip the new belt on then cut the remaining half of the belt off. One thing to be aware of is the VVT is a taller engine because of the timing gear situated on top of the cam cover. On the Westy I had to fit an air scoop to clear the engine top, the Replicar has more adjustment in body height but keep checking that the bonnet closes. You also have some work to do on the headlight electrics, when you are ready for it I have a list of differences between mk1 and mk2.5 donors that I made for the Westy, not all will apply to the Replicar but some will and you may as well benefit from my experiences. Good idea for the timing belt, will certainly give that a try. Be a while before we get to play with the electrics but will probably be back to pick your brains. Thanks
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Post by gwnwar on May 31, 2016 17:54:34 GMT
Are you in USA or UK and is the speedo/odometer in KM/H or Miles/H.. 57,000 KM is only 35,000 Miles 60,000 Miles > 96,500 KM.. Just saying..
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wraydon
Newbie
Donor : 2003 MK2.5 Six Speed
Posts: 8
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Post by wraydon on Jun 1, 2016 14:06:29 GMT
Are you in USA or UK and is the speedo/odometer in KM/H or Miles/H.. 57,000 KM is only 35,000 Miles 60,000 Miles > 96,500 KM.. Just saying.. Ah, I see your point. I am in Berkshire UK, near Heathrow airport, so it is in miles. Would have liked a 35,000 miles donor but the one I have will do nicely.
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wraydon
Newbie
Donor : 2003 MK2.5 Six Speed
Posts: 8
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Post by wraydon on Feb 2, 2017 22:27:26 GMT
We haven't posted for quite a while,the dismantling of the donor car is well documented on here and we had nothing to add. However, we collected the kit last week and I thought I would post a picture.
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