5 speed conversion au series 3 wagon

imbhvn · 23-01-2012, 04:53 PM

Hey guys im looking at doing a 5 speed conversion on my wagon as the auto is starting to play funny games, just wondering whats involved in doing it? Does the auto tailshaft work with the manual box or are the yokes different? do i have to do anything with the bcm or is it un affected? Any help and instructions will be greatly appreciated. Thanks in advance

T3man · 23-01-2012, 04:58 PM

Different ECU

Same BEM

Different loom

Different yoke I think and different length tailshaft

However the ECU/BEM can be reprogrammed by your friendly Ford Service department.

Then there's the hardware like pedal box that has to be swapped - although I believe Mal Woods Automotive can do a "add-a-pedal" conversion to your existing pedal box which will save you lots of work.

Anything else I've forgotten someone will fill in the gaps I'm sure.

PS If you end up keeping it auto I have a few lying around both for the 4.0L and 5.0L motors.

imbhvn · 23-01-2012, 05:59 PM

Definately will be going the 5 speed as ive always wanted to anyways, would a ute tailshaft be alright for the conversion? as thats what the gearbox came out of.

T3man · 23-01-2012, 06:07 PM

I expect that would be good.

eb91xr6 · 23-01-2012, 06:21 PM

tail shaft should be the same,
ecu change over is the quickest way,
alow a whole day to do it and the malwood pin saves you hours best money spent and just cut your brake peddle down, have a few mates handy as the auto box is heavy

imbhvn · 23-01-2012, 06:58 PM

Im buying a complete conversion, ecu,loom etc etc, but didn't say anything about tailshaft so just wanted to clear that up.

Also, just pressure tested my fuel, came back as 70 kpa and lost pressure straight away, no fuel leaks, im told that the pressure should be 270 kpa? so ill now be replacing the fuel pump aswell as the transmission :(

bartsau · 24-01-2012, 12:58 AM

I have done exactly what you want to do. I have converted my series 3 au wagon to manual. Love it and would highly reccomend it. Ecu is different and may be able to get it flashed but I just replaced mine. The driveshaft was a different penthouse but I can't remmember which way as I had my mechanic fit it all. Pedal box is easy to change. Don't need to change any wiring looms. Only difference will be the auto inhibitor which you just lop and then the deactivation of cruise control when the clutch is depressed. For more info just have a look through my build thread there is more there. Also any more questions feel free to ask. Give it a few months and I'll even tell you how to convert it to a v8....got you thinking yet?

blueoval · 24-01-2012, 01:59 AM

Watching this thread with interest. Will be performing this conversion on my sedan sooner later. biggest issue is getting my hands on a tail shaft. need one to suit live rear. hard to find. but not impossible. i have a manual ecu to put in but i also can fash tune as well with either xcal or j3.

bartsau · 24-01-2012, 06:33 AM

Trying to find the correct tailshaft is not easy. Mine cost 400 and is a lot stronger than standard as it is built with the intention of one day handling a motor with something around 450hp.

blueoval · 24-01-2012, 10:03 AM

Quote:

Originally Posted by bartsau

Trying to find the correct tailshaft is not easy. Mine cost 400 and is a lot stronger than standard as it is built with the intention of one day handling a motor with something around 450hp.

Thing is I currently have a full alloy XR tailshaft with balancer to suit a ute in my possession already. If needs be, I may need to modify that to suit my application. I suspect it will cost me about the same as yours to modify. I'll be darned if I have to pay as much as $400 for an stock steel version from a wrecker.

imbhvn · 24-01-2012, 03:13 PM

Well, the conversion came out of a ute, and the guy told me he will supply the tailshaft for an additional $100, im just hoping it fits? although i assume utes and wagons would rung the same shafts?

Need to know 100% if to get the shaft or not. as im picking up the conversion after work tomorrow, then will be doing the conversion on thursday which needs to be finished so i can get to work on friday

blueoval · 24-01-2012, 03:29 PM

wagons and ute tail shafts are identical in length and fitment. But they are not interchangeable with sedans, and vice versa. You should be fine with the ute tail shaft and it fitting your diff. Sedans get harder as some XR's came out with IRS diffs so the length and fitment differs to live rear diffs. As far as I am aware, all utes and wagons came with live axle diffs. So in saying that, it should be a direct bolt on.