Five-speed 1600E

Q I have a 1970 Mk2 Cortina 1600E and I’d like to fit a five-speed Type-9 gearbox to it, keeping the Crossflow engine. What will be involved? And will the centre tunnel have to be enlarged? David Jones UK

A As your car is a 1970, you may have to establish whether it’s a Series 1 or Series 2.The difference between them is the floorpan. Series 2 cars will allow the gearbox to fitwithout modification, but if your car is a Series 1, there’s a box-section stiffener that runs under the gearbox tunnel.This will need to be removed and strengthened accordingly. You’ll also need to make a new gearstick hole in the appropriate place.

The good news is that the gearbox will mount straight up to the Crossflow, but will then have the starter motor on the wrong side.This can be sorted out by fitting an RS2000-style alloy bellhousing (available from Burton Power), which has provision for the starter motor on both sides.

The original gearbox crossmember can be used if it’s turned through 180 degrees.You’ll need to get a new prop shaft made up — Propshaft Services can do this for you.

Lastly, the Mk2 Cortina uses a hydraulic clutch, whereas the Sierra is cable.To keep the hydraulic system, Retro Ford can supply a concentric release bearing that will plumb up to the original system.

Flat battery

Q My Mk2 Escort seems to struggle to charge its battery, which is located in the boot, so much so that I constantly have to recharge it when not in use. If I drive it even briskly its charge levels drop right into the red until I slow down again.

I’m guessing that my alternator simply can’t cope, but is there a better charging alternator available from another Ford rather than getting one from a race specialist? The engine is a

Pinto with a mild cam and twin 40s, and I’m running a five-speed ’box. John Lawton UK

A There could be a many things wrong, which are difficult to diagnose when you haven’t got it in front of you, so it’s going to be a case of working logically.

First, check the battery condition, or have it checked. If the battery’s shot, it won’t hold the charge regardless of the state of the rest of the system.

Next, you need to check the voltage output at the rear of the alternator — what it’s actually producing — and you should see over 14 volts. Having the battery in the boot shouldn’t really cause any problems.You may suffer some voltage drop when starting the car, but charging should never be a problem. Finally, check all the connections on the starter and charging systems including the earths.

If you want a higher output, use a DOHC Sierra alternator — this is a 70 amp unit. Swap the front pulley from the Sierra onto your car as well — this will bolt straight on.