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As many of you know from following my earlier post, I have just done a MAJOR transformation on my 2002 IM... New 2275cc engine with 44 IDF Webers, 042 Heads match ported and polished, Engle w-110 Cam, etc... 1 5/8" A-1 Sidewinder with heater boxes, new Kennedy Stage 1 with dual-friction clutch disc, and new KCR Transmission Super-Street with 3.88 gears and .089 4th. Suspension: new KYB Gas in front and Gas-A-Just in rear, Sway-A-Way 3/4" sway bars front and rear, and 26mm Torsion Bars.

In the shop nearly 4 weeks getting everything installed and sorted and just driven my first few miles so really early in break-in cycle on everything.

Impressions: Enough power to make me smile big, but not so much as to get into trouble. Exhaust sounds spectacular! Solid acceleration and you can feel the cam start to do it's job at 2000rpm. I haven't run much above 4000rpm yet, but I expect it to drop off before 5000 as I asked for low-mid torque over high rpm.

Problems? We have spent two full days trying to adjust the shifter including putting in new bushings and yoke where the shaft connects at the back tunnel... Reverse, first and second shift well. Fourth seems pretty easy to find, but 3rd gear takes 2-3 tries. We've adjusted the shaft until we're blue in the face... Also, on deceleration especially, it whines in all gears like an old truck tranny. I did replace the front trans cone mount with a Poly-urethane one so thought it might communicate a little more noise, but didn't expect what I'm hearing.

I'm hoping that things will loosen up and sort themselves out with some miles so plan to drive a lot this weekend. What are the chances? Hate to have to pull that new tranny out and be down another couple of weeks or more to send back to KCR, though I talked to Kevin last night and he's more than willing.

Thoughts?
1959 Intermeccanica(Convertible D)
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As many of you know from following my earlier post, I have just done a MAJOR transformation on my 2002 IM... New 2275cc engine with 44 IDF Webers, 042 Heads match ported and polished, Engle w-110 Cam, etc... 1 5/8" A-1 Sidewinder with heater boxes, new Kennedy Stage 1 with dual-friction clutch disc, and new KCR Transmission Super-Street with 3.88 gears and .089 4th. Suspension: new KYB Gas in front and Gas-A-Just in rear, Sway-A-Way 3/4" sway bars front and rear, and 26mm Torsion Bars.

In the shop nearly 4 weeks getting everything installed and sorted and just driven my first few miles so really early in break-in cycle on everything.

Impressions: Enough power to make me smile big, but not so much as to get into trouble. Exhaust sounds spectacular! Solid acceleration and you can feel the cam start to do it's job at 2000rpm. I haven't run much above 4000rpm yet, but I expect it to drop off before 5000 as I asked for low-mid torque over high rpm.

Problems? We have spent two full days trying to adjust the shifter including putting in new bushings and yoke where the shaft connects at the back tunnel... Reverse, first and second shift well. Fourth seems pretty easy to find, but 3rd gear takes 2-3 tries. We've adjusted the shaft until we're blue in the face... Also, on deceleration especially, it whines in all gears like an old truck tranny. I did replace the front trans cone mount with a Poly-urethane one so thought it might communicate a little more noise, but didn't expect what I'm hearing.

I'm hoping that things will loosen up and sort themselves out with some miles so plan to drive a lot this weekend. What are the chances? Hate to have to pull that new tranny out and be down another couple of weeks or more to send back to KCR, though I talked to Kevin last night and he's more than willing.

Thoughts?
Chuck, your new engine sounds like a real torque monster. Henry (at IM) started my 2275 on Thursday. It fired-up, first try, and immediately settled down to a nice idle. The engine doesn't have any leaks, but it's blowing a bit of oil through the dip stick.
My engine is built for more top-end power, and should be good for 6500 rpm ( Web 86b cam, 1:3 Pauter rockers, and 9.0:1 compression).
As soon as the engine is broken in, and the fuel injection computer has gone through its learning curve, I plan on taking it to a dyno shop for some fine-tuning and hp numbers. I'm hoping for 130-135 rwhp.
Hopefully, the shop will get your IM shifting properly soon.
More impressions... Just put another 20 miles on her. The good: corner's like a slot car and the engine seems to breathe better with every mile. The bad: leaking a few drops of oil that I haven't investigated yet. AND the ugly: The transaxle sounds like its gonna detonate any minute. My best comparison is an old rock-crusher truck tranny like the 50
I'm afraid that you already know this, and I hate to be the bearer of bad, confirming news, but you've probably got a bad forward bearing on the front half of the transmission input shaft. It is accessible (and changeable) by removing the nose cone and getting at it from there, but if that one's DOA then I would question what else is going on in there and, if it were mine and it's also new, I would get the builder to tear it down and re-do it til it's right.

That particular bearing (caged rollers) seems to be a weaker spot in these transmissions and it makes them seem to whine in every gear (although 3-4'th might be louder). While I've heard of any number of "cures" from changing to synthetic oil to changing from synthetic to running Marvel Mystery Oil, nothing I've seen totally cures it except for a rebuild to get the bad bearings swapped out.

It WILL be louder with a Urethane front mount (regardless of whether it's good or not), simply because THAT's where the noisy bearing is and the harder urethane transmits noise much more eficiently, but the urethane also points to the bad part big time. You probably don't need a Urethane front mount with that level of power, IMO, but that's up to you. It'll be quieter, once rebuilt, with a rubber front mount bushing.

Sorry, gn
Thanks for all the thoughts! Somewhat in order that they were asked...

1) Redline GL4 Synthetic in the transaxle
2) EMPI Shifter with the trigger lockout reverse and it is "new" with less than 2000 miles. NEVER had a problem with it before the trans swap.
3) My mech says it sounds like differential noise suspecting that the ring and pinion are too deeply seated together, but Gordon's post makes a lot of sense as well. Seems to be shifting into 3rd a little better as long as you hit it with some authority. Limp wrist and it just won't go.
4) I've still got the original nose mount and it was fine so I'll likely swap it for the poly unit...

Bottom line is the transaxle is coming out and going back to KCR. Kevin is a great guy with an even better reputation on all the boards so I have no doubt he'll make things right for me. I'll post progress, but it will take probably 10 days to round trip ship and give him a few days "re"build time.

Thanks all!
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