Gearbox change

[XRated]

Hey guys I don't usually like asking for help, but I need someone to come and help change my gearbox soon. I don't know what exactly needs to be unbolted/disconnected etc so I need the assistance of someone who's done it before (not removing the engine).

The only problem is, I am only really able to do this early and would need to stop working on it before 5pm (working a lot lately).

So if you're free before 5pm on Thursday (tomorrow), Friday, Sunday, Monday and wanna lend a hand can you PM me. Otherwise next week Tuesday-Thursday I am free all day/night. I'll supply lunch and a few beers for those willing :party3:

I'm in the SE suburbs of Melb.

[Damo]

I can probably give you a hand on Sunday ? I'll let you know. There's not much that needs to be disconnected etc. Have you done the pedal box yet ?

Here's a breif rundown on what you do and the order I would do it in.

Get the car up nice and high on ramps/stands.
Disconnect Battery
Undo Tbar and surround thingy
Disconnect handbrake
Undo tail shaft and remove, block off the gearbox - 15mm and 18mm
Unplug Gearbox Loom
Unbolt starter motor and get it out of the way - 13mm
Undo trans cooler lines if you have one and get them out of the way
Undo kickdown cable (or is that a 3 speed thing) ?
Unbolt crossmember to chassis bolts but not all the way undone - 17 mm
Remove lower sandwich plate and undo torque converter bolts
Crack off all the bellhousing bolts and remove but leave a couple on there - 19mm and 13mm
Undo engine crossmember bolts -13mm
Put a troley Jack under the trans and remove the crossmember bolts
Undo remaining bellhousing bolts
Slide the trans back and lower, remove from under the car
Unbolt flex plate and Remove

Don't think I've forgotten anything there.

Now putting the manual in.

Bash the spigot bearing into the crank
Bolt up the flywheel about 70-75 Nm and give it a wipe with metho
Give the presure plate a wipe with metho too, Bolt up the clutch/presure plater with alignment tool, make sure it's pretty spot on before tightening it up, give it about 27Nm
Grease up the thrust bearing slightly
Get the T5 positioned on the Jack under the car and slowly raise it up till the input shaft is about level with the centre of the clutch, then try and manouvre it forward and in, you may need to sping the output shaft till it feels like it's gunna go. If you can get it all the way in just try get a bolt or two started and that will pull it in, or alternatively use some clamps or something, Don't forget to put the sandwich plate in first though.
Once the trans is in do up all the bellhousing bolts to FT
Do up the crossmember bolts on the trans and engine
Reposition started motor and do up bolts
Refit tailshaft and do up bolts as tight as you can lol, or use some locktite (trust me) ;)
Re connect handbreak and adjust
Connect clutch cable and stove to the fork
Plug in the trans loom
Fit shifter and gear boot
Ground the starter Relay
Reconnect batery
Enjoy!

I think that's most of it, assuming the pedal box is allready in.

[XRated]

Whoa Damo! Thanks for the info!! The one on ford-tech lacks detail for a first-timer like me.

I've unbolted the shifter and handle etc, disconnected the trans cooler lines, and loosened the cross member bolts. I don't know how to disconnect the handbrake and loom etc.

I got the pedal box in no worries, but I am now worried that I fecked my steering column. I won't know until the car is running though.

If you can let me know about Sunday that'd be awesome.

[Damo]

Cool, the pedal box is the worst part I reckon. To disconnect the handbrake you should loosen it off under the drivers seat then unclip it on the passenger side of the gearbox once there is enough slack. The Loom should just unplug on the passenger side of the box.

[oneredED]

Luke, I just did this conversion, and what Damo has said is pretty much spot on. I will say this though, do not force anything. Be careful not to strip bolts ;)

Bash the spigot bearing into the crank

Errr, i was told not to BASH it in, we did it carefully LOL.

Oh, and depending on the box you have, the looms may not fit together at all due to different plug types... I have yet to work my looms out :P On the upside, it will run fine without the box loom plugged up, and just the speedo wires, but you'll have no reverse lights haha ;)

Jared

[Damo]

haha Jared, I still don't have reverse lights on my EA i'm just carefull when i'm reversing. Also yeah i didn't mean bash bash, just tap it in with the hammer. lol :P

[EDXR6T]

Originally Posted by Damo

don't have reverse lights

lol sound's like my old ED taxi :P
and that was an auto : i wish i had a manule

[d_slayer]

if it is an ef or above.. dont you need another switch for the clutch padel for the cruise to work and i think the plug for that is there but someone please confirm this

[SWOOP]

doing one on my old ed too, we ripped all gear out of donor tonight came out suprisingly easy ,tommorow pedal box goes in ,box will go in once a few new parts have been bought ,newclutch etc

one thing I really need is exact details on what wiring needs modding/used to make work with the standard ED smartlocked auto ECU , would use a manual but getting a hold of an XR manual one is a bit to much $$$$$$ ,
I have the loom that goes from manual up to main loom , is it plug and play or do I need to swap pins etc,

[DOMN8N]

yo damo where abouts is the kick down cable on 4spd auto eb

[EFFalcon]

4 speeds don't have a kick down cable

[Damo]

haha I thought so, something was telling me it was a 3 speed thing.

[DOMN8N]

ok i was thinking kick down kable myne didnt have one when i put my moter
in

Took me 6 hours to do my conversion ED pedal box, EA Box, EB clutch and cable I think I created frankenford LMAO

[XRated]

The auto is finally out - a huge thanks to Sunny and Ash for coming over today, and to Damo who gets hammered with my stupid questions on MSN! Thanks guys.

Hopefully it's not long before the T5 is in now.... I can't wait!

Originally Posted by SWOOP

one thing I really need is exact details on what wiring needs modding/used to make work with the standard ED smartlocked auto ECU , would use a manual but getting a hold of an XR manual one is a bit to much $$$$$$ ,
I have the loom that goes from manual up to main loom , is it plug and play or do I need to swap pins etc,

Me too, can anyone help out? I am supposed to be getting an ECU soon but I might not have time to wait. The box is from an EF so I'm confused about wiring...

[Psycho Chicken]

Nothing will change, the boxes are all the same. Did you still need that gearbox loom I have?

Manual conversions suck! Worth it though.

[XRated]

Yeah Rob, that's what I'm wondering re. the loom. Do I need one from an EB/ED? Will it just plug straight up with everything if I have the right ECU and will everything work just like a factory manual Falcon would?

[Psycho Chicken]

If you have the ECU and the loom it will work perfectly.

[wilbur]

Am I missing something? Why do you need to change the ecu is it something to do with cruise control or smartlock. I dont have either EBII pre smartlock????

[NZ]

In EBII the trans and engine are a combined unit. Pre it is not there is 2 seperate units. The problem is when you have an auto ecu rnning a manual drveline you run into problems with the idle having a mind of its own, not being able to get the car to self test etc to name a couple. There's way's round it but the best option is to just get the manual ecu.

[wilbur]

Originally Posted by NZ

In EBII the trans and engine are a combined unit. Pre it is not there is 2 seperate units. The problem is when you have an auto ecu rnning a manual drveline you run into problems with the idle having a mind of its own, not being able to get the car to self test etc to name a couple. There's way's round it but the best option is to just get the manual ecu.

Thx NZ helps heaps