Budget Turbo Build... From the ground up

[illinipo]

have fun with the shift cables... nobody ever mentions that you have to cut your butyl rubber liner on the floor to get to the cable bracket... not good... but no other way to do it.

imo, will be easier to just leave the shifter till the swap day. speaking from experience here lol

[AcIdBuRn02ZTS]

ran into a little problem... cm clutch will not work with FS flywheel... nor will any other friggen aftermarket clutch... exept the one i'm having custom made by southbend clutches.... they seem to know their stuff....

Andy guarenteed me that the clutch he will build will support 450+ ft. lb of torque off the crank and is warrented for 12/12,000.... no questions asked.

I'm sending him my FS flywheel tommorow and he's going to go from there... and he said it would be back in my hands by this Thursday.... for $475 shipped

-AcId-

[sleeperlove]

How is it that no aftermarket clutches will work with the FS flywheel?

[AcIdBuRn02ZTS]

the FS flywheel is designed to work with the factory clutch setup... the other companies such as exedy... cluctch masters... etc... have a comletely different design for the pressure plate which will only bolt to that companies flywheel...

basically from what ive been told by massive....

most aftermarket clutches were being made from modified factory pressure plates.... but ford discontinued the pressure plate because of the problems everyone was having with the stock clutch... and redesigned it... in turn... the aftermarket decided to design their own flywheel/pressure plate combo instead of using the stocker... because apparently the new design stocker is at its limits out of the box...

if any of that makes any sence....

anyways... i got news today that my clutch will be here tommorow so all is good... apparently... the FocusSport flywheel... is the exact same as the fidanza flywheel... just a different name lasered into the casting... so their clutch kits they offer are a direct bolt up... so if looking for a clutch and have an FS or simular flywheel... check out www.Southbendclutch.com ...... everything else that I ordered is laying in the floor... and im starting to swap tommorow night... many many pics and a possible write up to come later.

thanks guys!!
-AcId-

[AcIdBuRn02ZTS]

everything is going smoothly so far... not too much left to drop the tranny out of the car.... then hopefully i'll get all the linkage and lines ran.... then get the new tranny up in place....

anyways... more info to come soon

-AcId-

[illinipo]

aw boo i hate you, I cant start until later tonight

good to hear its going well.

[AcIdBuRn02ZTS]

just a forwarning.... while your pulling things apart... go on and drop the k-member... it makes things MUCH easier.... otherwise the larger getrag unit will not fit... it either hits the crossmember or the pressure plate... i would also suggest an extra hand or to to get the tranny up in place... it was a snug fit without dropping the motor down.

ive so far also been able to use the non-svt ps line... but i wont be possitive on that until i drive it...

btw...

transmission is in!!! pedal assembly and shifter assembly are installed... tommorow... just gonna finish wiring... plumb the clutch.... button up the front suspension which btw.. my suspicion of a failed wheel bearing was very correct.... had a good 1/2" of play on the pass. front... but both sides are replaced now and all is good... basically... the hard part is over with.

i have tons of pics but the wont be up untill i can get them all up at once...

do have a quick question... local dealer didnt have the honey.... and the only suggesstion i had found that I could get locally was Royal Purple GL-4 comp. 75-90... will this do the trick? also... does anyone have pics of the drain and fill ports on this tranny? I didnt look it over all that well while installing it...

thanks guys
-AcId-

[illinipo]

dunno about fluid for the getrag... but if i had to guess id say RP synchromax, second to the xt-m5-qs.

yeah, theres a way around dropping the subframe but it is not fun. I just now popped my tranny over the pressure plate after 5 hours of pushing and shoving with my friend. I have my engine on a chain brace. When on a lift, dropping the subframe looks to be a pita... remvoing power steering, etc... so we took my fans out and pushed the motor forward, clocked the trans -15 degrees or so (ccw), and eventually we got it over the k-member and around the pressure plate, to grandmothers house we go.

best of luck! smooth sailing from here, looks like you did a good job

[AcIdBuRn02ZTS]

car is back on the road... and wow... its a blast to drive...

have a few lose ends to finish up tommorow morning before I put any miles on it....

noticed the clutch master cyl. is seeping a little inside the car... it might quit... so im gonna keep a CLOSE eye on it and the bf level...

the gear ratio's in the tranny are amazing... keep the car in the powerband at all times basically...

anyways...

and btw... the subframe is simple to drop down to clear the tranny... it has 6 bolts in it... and you remove the 10mm bolt inside the car that holds the steering shaft to the colum.... then you can drop it down a good 5" or so which is plenty to clear the tranny... without messing w/ the steering rack on lines...

well... ATX to Getrag swap in basically 2 days... not too shabby '

i'll get the pics up tommorow when i get a chance

thanks alls

-AcId-

[AcIdBuRn02ZTS]

ok... picture time..... but first... a word of advice... when doing something this intensive... DO NOT GET IN A HURRY AT THE LAST MINUTE!! i made several large oops because of getting in a hurry to get it on the road... one of which was I didnt install the driver side lower strut mount bolt... and 2... i didnt tighten the lower balljoint bolt on the same side... which could have cost me... but all is good now... got it back in the air and went over it with a fine tooth comb to find anything else I had missed... and got most everything working properly....

anyways... on to the pics...

A familuar site...


my Southbend Clutch kit...




pile of ford goodies


started pulling front end apart...


pulled knuckles and hubs on both sides for wheel bearings while I was at it


axle shafts out


unhooked everything and dropped tranny... litterally...


just to show my appreciation of the autotragic...


installed shifter assembly


installed pedal assembly


installed FS flywheel... which SBC surfaced for free while they matched up a clutch for my app... I must say im VERY satisfied with their customer service


ceramic/kevlar clutch kit


clutch installed


1st attempt at tranny install... before dropping the k-member out of the way...
and my helper showing his appreciation of me


tranny up in place... everything going back together


all buttoned up... clutch bled... brakes bled...


re-installed some of the interior pieces... (i'm in need of a shift boot retaining ring if anyone has one theyd let go of for cheap... mine was broken upon recieving)


and the goodness... which still needs to be cleaned...


im getting used to driving it... slowly... the clutch is pretty stiff... but is streetable... still have some kinks to work out... a few heatshields that were bent up in the process of the install i have to fix... stupid rattles...

one other thing... I used the SVT tranny harness instead of the ATX harness... and the speedo doesnt do anything... is there a remedy for this? do I need to modify the atx harness and use it instead?

anyways... thats it for now... hopefully I get it all back together and cleaned back up again soon.

thanks guys!!
-AcId-

[illinipo]

lol, i definitely remember my first atx appreciation pic haha nice one

the auto oss has 2 wires, not sure what their voltages are.. but the mtx75 has 3 wires on its vss, +12, GND, and the sensor output. hope that helps... i have no idea whats wrong with yours. it might not be getting ground or power.

have you wired either of the two clutch position sensors?

[AcIdBuRn02ZTS]

I left them unhooked... had no need for them... I did the start circuit... but the rest i just used the svt tranny harness and plugged everything in then plugged the harness directly in... which is what I think the problem is... i think the svt's engine harness may be wired differently aswell as the tranny harness... but either way.. its driveable

-AcId-

[sporadic]

Nice work. I just used a zip tie to hold up my shifter boot.
Since it's under the boot you can't actually see it and it keeps it held up just fine.

[AcIdBuRn02ZTS]

my shifter boot up top is fine... its the plastic ring that snaps into the console that is the problem... its broke so it wont hold in place at all... prolly gonna replace it soon if I cant rig it... i mean... it is just a shift boot and all... aslong as it looks good... it wont matter i suppose

i now have around 200 miles or so on the setup... and i put it up on the lift at work today and fixed my many heatshield rattles... everything is going good so far... thinking about picking up the FR short shifer for it and going from there... we'll see

thanks for the input guys

-AcId-

[illinipo]

could you do me a favor and post all the the check engine codes you have (if any)? im trying to diagnose a few things before I call my tuner... here is what I have

p0705 tran rng s cir er
p0713 tran fld tmp s ckt hi in
p0750 sft noid a er
p0760 sft noid c er
p0765 sft noid d er
p0770 sft noid e er
p1746 epc noid open circuit


PS shift boot is 10 bucks at Tousley

[AcIdBuRn02ZTS]

I had three when I checked... I'll go pull em up real quick and list them...

:EDIT: My 3 codes are...

P0705
P0770
P1746

to get these codes to go away... you'll either have to swap in an mtx ecu or have your tuner delete all of the atx functions from your tune

-AcId-

[illinipo]

my thinking is you can find the two wires (or one wire) for the epc solenoid and connect them with a big resistor (or connect the one wire to GND with a resistor), so that takes care of p1746

For the trans temp, im thinking find the two wires and connect them with a big resistor. Then it will have low output.

and according to this document
http://www.tankota.net/repair/Repair...e/cip0705p.pdf
we need to feed the range sensor input to the PCM 12V to make it think it is not in P or N. That takes care of p0705.

p0770 will be much easier to deal with in the tune.


thanks for posting that, really helped me to figure it out.

[AcIdBuRn02ZTS]

Well... so much for smooth sailing...

I got half way to work today when the car decided it didnt want to move anymore... so i limped it into a parkinglot... clutch rattles like crazy unless depress the pedal.... it has a slight want to pull in 1st and reverse... other then that... nothing... it free revs in all gears with the clutch out....

i can fell the shifter dropping in gear and everything... so i dont know... hopefully its not the tranny itself.

anyways... if you can... help me out in the Shift-It area.

-AcId-

[AcIdBuRn02ZTS]

well.. ive started pulling the tranny back out to find out what went wrong.... im gonna take my sweet time this week while putting everything back together... but the tranny should be on the ground in a few hours so i'll let you alls know what exactly has failed before I ship it off to SBC for replacement.

thanks
-AcId-

[AcIdBuRn02ZTS]

well... I found the problem... i dont have any pics but lets just say the clutch disc came out in more then one piece... it literally had ripped the center sprung hub off of the friction material ring....

now the bad part... i installed the clutch setup how it came out of the box.... the disc itself was not labeled as for which direction the disc should go... so I installed it how it came in the box... which apparently wasnt the right direction. the instruction sheet says nothing about which way the clutch disc should go.. but from what ive been told... the ceramic material should have gone towards the pressure plate... not the flywheel... so i'm not sure if SBC is going to warrant it or not... God I hope so... I dont quite have another $450 to buy another clutch setup at the moment... and this car is my dd... so im not sure whats gonna happen. I'm gonna ship it back on monday and see what they say... they dont know as of yet that I think it was installed backwards... and they didnt ask me that over the phone either... and since it wasnt labeled... who knows...

anyways... im kinda in a pickle at the moment... but I guess I'll just have to wait and see.

thanks guys.
-AcId-

[AcIdBuRn02ZTS]

here are the carnage pics....







uber fail:


it doesnt appear to have damaged the flywheel or the pressure plate... so those might be saveable..

here is what fell out when i started unbolting the pressure plate....


guess I found what the rattle was... o well.. im pretty sure SBC is gonna take care of it without too much problem... so hopefully i'll have the car back on the road asap.

thanks guys
-AcId-

[paulhaskew]

ouch, one reason why I didn't go with a company that modifies stock or other company clutch assemblies...

[FocusSportVP]

Man, what a bummer.