Manual conversion kit

albanycobra · 28-09-2006, 10:28 PM

Ok Guys I'm sick of my old shitbox auto and
have bought a AU manual conversion kit from the
wreckers. It includes everything from T5 to manual ECU.
The kit comes from a AU II ute.
Can any of you guys give any tips when making the change over
or anything I should look out for?

:

EvilChief · 28-09-2006, 11:58 PM

lotsa beer ;)

nothing too over the top really, hardest bit will be the wiring, which u know a little about is also a peice of cake

hotwire the neutral switch and reqire the reverse lights, simple as that.

expect a lot of grases on ur nuckles and make sure ur vocabularey of swear words is up to scratch

RspecAU · 29-09-2006, 12:21 AM

Quote:

Originally Posted by albanycobra

Ok Guys I'm sick of my old shitbox auto and
have bought a AU manual conversion kit from the
wreckers. It includes everything from T5 to manual ECU.
The kit comes from a AU II ute.
Can any of you guys give any tips when making the change over
or anything I should look out for?

:

Did u get a tailshaft with this package? may want to look into that to

Racecraft · 29-09-2006, 04:49 AM

ute and sedan tailshafts are different
The manual has a dampening ring on the tailshaft, so if you have a sedan getone of those
Don't forget to order the spigot bearing from Ford

Racecraft · 29-09-2006, 05:49 AM

Another thing too:- Depending on what series your car is, you might have issues with the SII ECU going into a smartlock AUI

Also dont forget to get your key reprogrammed to match the new ECU and BCM

GlennBA · 29-09-2006, 11:11 AM

We just did mine over to manual and its the best mod i've done to the car.. its completely different to drive in a good way.
You have to go to ford to get your key reprogrammed to the new ECU, the car will not start and will probably immobilise itself if you don't.

XR6-VCT-2000 · 29-09-2006, 11:42 AM

Might be worth adding a nice thick plate of steel for the firewall where the cluch is while your at it , save the dreded droping clutch/cracked firewall drama later... just a suggestion , allthough you've probably allready thought of that anyway ? , cheers ;) .

ClassicAU · 29-09-2006, 11:52 AM

Hi albanycobra, how much did this kit cost, if you dont mind me asking? Did you just get it from a wreakers, or are these actually available as a full kit? i am just trying to decide what would be the next mechanical mod i look into doing.

albanycobra · 29-09-2006, 08:05 PM

Trouble encounted so far
1- The Auto tail shaft is to long, will need cut and shut.
2- series 2 pedal box has different brake booster stud pattern, will need drilling.
We got the box fitted and all is well so far. Will just put inhibitor switch
in nuetral to get car going before changing wiring and ECU.
The conversion kit was $1830 from Wollongong wreckers NSW.

AU3 HERROD XR8 · 29-09-2006, 11:56 PM

hi guys, i got a question thats got nothing to do with the manual conversion, but though since its about transmission i did'nt want to start another thread, soo here's my question..
Is it possible to throw a 2006 XR 6spd auto transmission in an AU

b2tf · 30-09-2006, 12:00 AM

Quote:

Originally Posted by AU3 HERROD XR8

Is it possible to throw a 2006 XR 6spd auto transmission in an AU

not without a lot of modification.

AU3 HERROD XR8 · 30-09-2006, 12:05 AM

hmmm, how much modification would someone be looking at, and is it worth the cash

b2tf · 30-09-2006, 12:06 AM

To be honest I dont know much about the actual work involved, but I think at this particular point in time your biggest problem would be finding a box? They go for around $8k from Ford.

EvilChief · 30-09-2006, 12:30 AM

the biggest problem will be the electronic controller, as for the mechanical side of things i dont see a reason why it shouldnt fit quite easily.

XR6-VCT-2000 · 30-09-2006, 02:48 AM

Quote:

Originally Posted by AU3 HERROD XR8

hi guys, i got a question thats got nothing to do with the manual conversion, but though since its about transmission i did'nt want to start another thread, soo here's my question..
Is it possible to throw a 2006 XR 6spd auto transmission in an AU

Someone correct me if im wrong , no worries ;) , but seeing no AU model falcons came out with a 6speed auto , and the ecu controls alot of the auto functions, i think you would find you wouldnt be able to get an ECU to match , unless you used the ecu from the car that had the 2006 xr 6speed ? , but then there is the problem of matching that up with the au BEM... or you could change everything and rewire everything , new ecu , new bem , new wiring / looms etc etc . might as well buy a falcon with a 6peed for the trouble imo if the above is the case . cheers .

EvilChief · 30-09-2006, 11:11 AM

there would be three possible solutions to that problem:

1: standalone TCU
2: BA 6 speed ECU, which ONLY controls the transmission, not the engine (BBM would be the easy part to make work, VCT would be the biggest issue)
3: full manual valve body and shifter, eliminating electronic control

Racecraft · 30-09-2006, 11:18 AM

the trans tunnel on the AU would be too small aswell....

albanycobra · 30-09-2006, 12:38 PM

Back onto the original thread, How many different tailshafts are available
for the AU, It seems there is an Auto one, a ute one and I can only assume
there is a dedicated manual tail shaft for the sedans?

bodes-sh · 30-09-2006, 01:00 PM

yeah i would think the sedans would have had one made just for them, but im not sure on the wheelbase of the utes, whether or not they are the same length as a sedan...your best bet would probably be to find either the car you got the box from, if it had a tailshaft in it, or find a wrecked manual sedan...unless someone else here knows somewhere else you could get one

GlennBA · 30-09-2006, 04:01 PM

Quote:

Originally Posted by albanycobra

Back onto the original thread, How many different tailshafts are available
for the AU, It seems there is an Auto one, a ute one and I can only assume
there is a dedicated manual tail shaft for the sedans?

Yes manual tailshafts are available for the 6cyl sedans. My tailshaft had to be swapped to put my 5 speed in.
Ute tailshafts are different.

albanycobra · 30-09-2006, 06:29 PM

I suppose cutting the tailshaft down will be cheaper than
Buying a Gen Ford manual tailshaft new.

Racecraft · 30-09-2006, 06:34 PM

Quote:

Originally Posted by albanycobra

I suppose cutting the tailshaft down will be cheaper than
Buying a Gen Ford manual tailshaft new.

source a 2nd handie and have it balanced.. I did that as I only had a ute manual jobbie, iirc the sedan manual tailshaft was $115 and $80 to rebalance it

albanycobra · 30-09-2006, 06:53 PM

Where do I find a manual AU sedan tailshaft? They'd be rare as hen teeth,
unless a shaft from another series fits. We tried an E series auto shaft and
it was to long aswell.

Racecraft · 30-09-2006, 07:01 PM

I just rang the local and they put it on the Parts Hotline... 30 secs later I was on my way to pick it up.. While they are rare'ish I didnt have any trouble finding one

mik · 30-09-2006, 09:05 PM

a good tail shaft place would be able too fabricate a newy if you were desperate.

albanycobra · 30-09-2006, 11:21 PM

Yeah thats way I'll have to go I suppose in regards to the tailshaft.
I was hoping to leave the Auto inhibitor switch plugged in
and select Neutral and leave the main Autotrans plug hanging,
I suppose doing this will bring the engine light on ?
maybe I should bridge the start side of the inhibitor switch and
set the switch to drive? Anyone fooled with this when it comes to
AU's?

Was hoping this thread could be a good technical resource for all
considering the conversion.

This what I've got so far
AU sII manual trans fits AU SI -straight fit no mods
AU sII pedal box requires booster holes redrilled to suit AU sI
AU auto tailshaft wont fit, Requires shortening by about 50mm
Auto centre consul just needs the gearstick boot insert fitted

Things still to sort
1-Inhibitor switch (what to set it at)
2-Final tailshaft lenght (maybe someone with manual can measure theirs?)
3-I have a manual ECU from the series 2 (will confirm later if swap over is possible.

Thats really all that is left to do. Can take some pics as car is on the hoist at the moment.

EvilChief · 01-10-2006, 01:08 AM

1: hotwiring neutral switch to perm on will not bring up engine light on

do not wire in D position as it will inhibit u from starting car ;)

2: sorry car is at mechnanics cannot measure, i got a custom light weight made up for 350 bucks ;)

3: cannot use Au S2 ecu in Au S1 due to smartshield/smartlock systems

albanycobra · 01-10-2006, 11:57 AM

Will having the main Autotrans plug (controls solenoides and the like) unplugged bring on the engine light?
Evil chief - So you just unplugged the inhibitor switch completely and
hot wired the harness plug? or did you leave the inhibitor plugged in and
selected park/neutral positions?

albanycobra · 03-10-2006, 10:24 PM

Auto tailshaft has to be shortened 60mm.
Price quoted $250 including new uni's
or a Ford Gen is $745.

EvilChief · 03-10-2006, 11:06 PM

left inhabitor switch in and crosswired it to be enagged permanently.

the harnes plug becomes obsolete, except for the reverse switch