T5 Conversion. 'progress'

Damo · 21-05-2005, 06:56 PM

Heya.

Started the conversion today with teh help of Sundeep. Lotsa fun was had with some very tight bolts, a bastard of a starter motor, a few oil spillages, including about 5 litres of tranny fluid. I was swimmin in the shit.

:

Didn't get as much done as we would have liked, but the 3 speed is out, and it should all be a lot easier from here on in. No more messy greasy parts. I'll post a few pics, cause pics are sik!
The old 3 speed and torque converter.

They empty space undeneith the car. I like this pic. :P

Shit everywhere in the garage, including the t5 and various other parts, plus all dads work shit.

:

And the fully sik EA!

Tommorow i'll check all the wiring, run the clutch cable, bolt up the manual flywheel, clutch etc. Separate the t5 from the bellhousing, and any thing else that needs to be done. Then hopefully tommorrow afternoon, or monday I might take a sikie, and we'll get the bastard going again.

Huge thanks to Sundeep! I felt sorry for you having to go to work. I wouldn't have got jack shit done with out ya mate, should all be worth it in the end, and i might have a new found love for my car. It's been ages since i've driven a manual Falcon!

If any one has any tips with putting the t5, post em up.

That's about it!

Cheers

Cheers

:

T_Terror · 21-05-2005, 07:36 PM

Good work dude, manual conversion is hte best mod you can do IMO.

Why are you unbolting the T5 bellhousing though? You should be able to stick the whole assembly in the trans tunnel and bolt it from the bellhousing to hte block.

Make sure you got a bit of room under the car and definitely get some help raising and maneuvoring the transmission while youre under there. Believe me, its not fun (or easy) doing it on your own.

MustangNicko · 21-05-2005, 07:38 PM

Get a new clutch and machine that flywheel. The last thing you want is a shit clutch and a bumby flywheel. Well worth it.

stockstandard · 21-05-2005, 07:41 PM

I found it easier to get everything in by fitting the bellhousing first and then pushing the gearbox in. I was doing it alone and it helped to take a bit of the weight and bulk off.

Damo · 21-05-2005, 07:45 PM

Quote:

Originally Posted by T_Terror

Good work dude, manual conversion is hte best mod you can do IMO.

Why are you unbolting the T5 bellhousing though? You should be able to stick the whole assembly in the trans tunnel and bolt it from the bellhousing to hte block.

Make sure you got a bit of room under the car and definitely get some help raising and maneuvoring the transmission while youre under there. Believe me, its not fun (or easy) doing it on your own.

Thanks for the reply. Yeah, my first car was an EA 5 speed and loved it.

About the separting bellhousing from transmission, It was just an idea me and Sunny had, as we thought it might be easier to bolt up the belhousing and clutch assembly separetly. Then bolt the t5 up to that ? No.. It wasn't really a matter of space, just thought it might be easier that way, as you say it's not easy to maneuver a transmission around, even with 2 people.

Damo

Damo · 21-05-2005, 07:51 PM

Nicko- The clutch is about 2000 ks old, and fly wheel was machined recently, i'll give it a clean up though with some 1200.

Stockstandard- Cheers mate, that was our theory. Would deffinately make things a bit easier I reckon.

MustangNicko · 21-05-2005, 08:36 PM

Id still get a new one and a freshly done flywheel, trust me ;)

Damo · 21-05-2005, 08:40 PM

Nah, she'll be right! Thanks anyways. :P

If the clutch lets go, i'll let you know, and then you can laugh.

PULLY6 · 21-05-2005, 08:49 PM

whats a new clutch/flywheel worth?

Damo · 21-05-2005, 09:35 PM

more than my EA is worth! haha nah. I dunno. $400 + for clutch + presure plate, depending on brand and quality, fly wheel mahining should be cheap. The teeth on mine are perfecto. It just has some very, very, very, MINOR surface rust from sitting on wet grass.

21-05-2005, 10:09 PM

Yeah, I did the same when coverting my ED fairmont to manual. New fly wheel (came with the box) and clutch kit etc. But did it in the same theroy of putting the belthousing on first and then the box in after that. Good luck with it anyway. Its well worth it. :eclipsee_

P.S agree with the below msg, just was lucky to get a good deal.

Sundeep · 21-05-2005, 10:14 PM

Screw machining and new clutch, was only done like less than 500km ago. It's only a EA, not a EL GT being converted or something. Some guys really need to adopt the "she'll be right" attitude ;)

Sundeep

InitialD · 22-05-2005, 12:00 AM

Sounds like its going well Damo ;) Hope you have it done asap.. You gotta beat jared again

22-05-2005, 12:34 AM

looks like its coming along great damo! makes me wanna convert my ED sooner...

im a huge fan of the "she'll be right" attitude too. lol

EFFalcon · 22-05-2005, 03:31 AM

great

should be much more fun!

ilsautomotive · 22-05-2005, 11:08 AM

She really will be right, trust me.

The clutch is an AP Racing clutch that I had put in probably 1000 kms ago. Admittedly I was learning to drive manual but still.

I never got around to changing the crappy fluid in this box but included some top of the range Transmax Z fully synthetic to address that.

dansedgli · 22-05-2005, 11:38 AM

:( I want a manual. I cant wait till the mini is on the road again!

We better get some good demo's when its done damo!! :eclipsee_

Manual is definately then way to go!

NZ · 22-05-2005, 11:51 AM

just give the flywheel a whipe with some spirits (not the drinky drinky type) when its bolted on to get rid of any grease or oil. if you use a white cloth you will beable to see the crap that comes off.

Damo · 22-05-2005, 07:15 PM

i'm over it!

The day started off well, picked up a clutch spring from Just Falcons, $2.

Got to putting the clutch on, all was going well untill I found one of the holes on the flywheel for the presure plate is stripped!!!! aghhh!

Sunny and Doug came around and we joked around for a bit, tried to think of a solution, but meh!. So not much got done :( I also found I don't have the circlip for the clutch cable to attach to the clutch pedal. $@$#@!!!11!

I'm over it, going to borrow my Nans VL after work tommorow, to get through the week. I'll get a new flywheel, and a couple of circlips, then back into it next weekend.

Jacko, the clutch is a heavy duty PBR clutch.

:

On top of all this, I left my glasses in the banged up EA 5speed at just Falcons, when i was grabbing the clutch spring. Had a panick attack when i was racing around the house everywhere looking for them tonight. I'm sure they'll still be in that EA or hopefully if someone was in that car at a later stage in the day they were handed in.

I hope it's worth it in the end, but knowingmy luck, i'll get the 5 speed happening and something else will f00k up.

Damo

Brent-EA Ghia · 22-05-2005, 07:22 PM

Ahh that sux, should make sure you have everthing for next weekend, and look forward to driving a manual!
I know i am but mines just gonna take a little longer ;)

Damo · 22-05-2005, 08:32 PM

yeah I can't wait to drive it manual. Should be soo much more driveable, i'll just need a diff ration change.

Oh I forgot to mention I dropped the flywheel on my pinky finger... ouch! The teeth dug right in! :P It hurt heaps!

Does anyone know how much a brand new flywheel is worth ? or if my old one can have the holes for the presure plate re-drilled, and might get it machined too ?

Thanks.

NZ · 22-05-2005, 08:45 PM

get it re drilled. a few people get ea flywheels drilled to take 4l clutches so you should beable to get something done. possibly get another 3 holes drilled and use them instead of the holes that are there now.

Gunns · 22-05-2005, 08:46 PM

You need a manual fly wheel cos they are much heavier than the auto one. as they drive the momentum (spelling) of the engine. So when you take your foot off the gas the car does not drop rpm real quick.

Qwikcorty · 22-05-2005, 08:54 PM

auto's dont have a flywheel, they have a flexplate that the convertor bolts onto. someone want to replace my clutch while there at it?

Damo · 22-05-2005, 09:16 PM

Haha, Al yeah I have a manual flywheel. sif auto one would work. Thye weigh about half of what a mnaul one does.

Haha Qwikcorty, clutches suck! so do those allignment tools.

Karl, good idea, i'll see if I can get it re-drilled.

Thanks guys.

SileNceR · 26-05-2005, 10:14 PM

i got three extra holes drilled for my HD clutch (so used all six, including the original three)

mr_efxr · 26-05-2005, 10:25 PM

Not too sure if an EA and EF flywheel are the same, however I got a brand new flywheel with ring-gear from a good source at Ford for $140.00 when I did my conversion. If your looking at a new clutch and pressure plate kit I can hook you up too. Just PM me for more details.

mr_efxr · 26-05-2005, 10:27 PM

Its a ball breaking operation, I got stuffed around with mine too. During the conversion copped cuts, bruises, strained muscles, headaches, but all worth it in the end I reckon. DONT YOU DARE GIVE UP.

Damo · 27-05-2005, 04:52 PM

: nah I ain't givin up just yet.

I found the right bolt for the presure plate, as one of the threads on the flywheel was slightly threaded at the start, so a longer bolt was required. This is the way it came, i'm not sure if it's dodgey or not. The Transmission was fine in Jacks car... i think.

:

So i have the clutch bolted up and aligned by eye. I couldn't work out how to use that stupid clutch tool, so here's hoping my aligning skills are good. Probably not though. It doesn't look aligned in this pic but that's just the angle.

I'm gunna go grab a torque wrench, something i've needed for ages now. Does anyone know how tight to torque up the presure plate, I know i've read it some where 20 nm sound right. ;) It's starting to come together again now. I think i deffinately have everything i need now. Maybe some more headache tablets will be neaded.

I keep thinking i'm gunna get it all back together and something is gunna stuff up though, i'm soo negative about this whole thing now.

She'll be right.. :gren: I hope...

Damo

NZ · 27-05-2005, 07:05 PM

You should be careful if your mixing and matching bolts. the 6cyl is naturally balanced so if you go using heavier bolts - even a few grams you'll probably get a vibration. I've never seen the clutch aligning tools you are talking about, but i imagine they are just like the input shaft on the box. Did you put the spigot bearing in the crank before you bolted everything on? the clutch tool i bet you just slide it into the end of the crank and it will hold the clutch plate in the right place while you tighten thepressure plate. if its not aligned properly you'll never get the box to slide in.