Well, had a little bit of good news, and then had it all erased with some really bad news. Had my neighbor come over and helped me get the transmission attached to the motor. That was the good news.
The bad news is I finally heard back from another person about the chips I observed on the two gears in the transmission. The chip on the reverse idler gear which is on a corner isn't a big deal. The chip in the middle of first gear is a big deal. Apparently it won't take much to break off more of the gear and then shell the transmission. I'm fairly bummed, not sure what to do now. Waiting to here back from Jeff, but the options aren't good. Major disassembly, more money I probably shouldn't spend on this thing. Not going to be driving the Scorpio to Carlisle for sure now. Crap.
Tuesday, May 7, 2013
May 5th, 2013
Post Mortem for the weekend.
Made sure transmission case was clear of the nasty looking fluid and filled it with the Ford stuff.
Started on what I thought was going to be an easy job. Remove automatic transmission harness and replace it with the manual transmission harness. Several hours later, stereo and changer removed, dash removed. Wires traced to all four corner's of the car. I think I can competently say that there is a variation is wiring from the automatic Scorpio to the manual Scorpio.
Jeff Herson sent me a picture of what we thought should be under the hood:
Observe the nice 8 pin wiring harness that runs right behind the MAP sensor. This car is an 89 factory equipped T9 Scorpio. This is the harness that runs down to the transmission and has the speed sensor, reverse, and I can't remember what the other connector is for.
Here is the same picture, but of my 88 Scorpio, automatic.
After looking through all three sources of information, Shop Manual, Electrical & Vacuum troubleshooting, and the actual wiring diagram, I am fairly certain the 8 pin wiring harness connector does not exist on the automatic transmission Scorpio. There is a 9-pin harness behind the radio (why I took the whole dash apart) that has the relevant wires for the transmission. At this point I decided to combine the two harnesses I had. Take the connectors from the automatic harness and use them on the manual transmission harness. The resulting harness is very long, but I think I can make it work.
At this point I was ready to attach the T9 to the engine. I wrestled the transmission onto my floor jack, got it into relative position and attempted to align the input shaft with the clutch etc.
No matter how I tried, the top of the transmission catches the tunnel before I can get the transmission high enough for the input shaft to enter the clutch. I messed around with it for an hour or more. I am going to get another floor jack tomorrow. With the addition floor jack, I am going to loosen the motor mounts, using the foor jack to support motor and hopefully get the motor to tilt back far enough for me to align the transmission and bolt them together. What a mess. It will probably be late tomorrow night or Tuesday before I can work on it again. Time is running short.
Made sure transmission case was clear of the nasty looking fluid and filled it with the Ford stuff.
Started on what I thought was going to be an easy job. Remove automatic transmission harness and replace it with the manual transmission harness. Several hours later, stereo and changer removed, dash removed. Wires traced to all four corner's of the car. I think I can competently say that there is a variation is wiring from the automatic Scorpio to the manual Scorpio.
Jeff Herson sent me a picture of what we thought should be under the hood:
Observe the nice 8 pin wiring harness that runs right behind the MAP sensor. This car is an 89 factory equipped T9 Scorpio. This is the harness that runs down to the transmission and has the speed sensor, reverse, and I can't remember what the other connector is for.
Here is the same picture, but of my 88 Scorpio, automatic.
After looking through all three sources of information, Shop Manual, Electrical & Vacuum troubleshooting, and the actual wiring diagram, I am fairly certain the 8 pin wiring harness connector does not exist on the automatic transmission Scorpio. There is a 9-pin harness behind the radio (why I took the whole dash apart) that has the relevant wires for the transmission. At this point I decided to combine the two harnesses I had. Take the connectors from the automatic harness and use them on the manual transmission harness. The resulting harness is very long, but I think I can make it work.
At this point I was ready to attach the T9 to the engine. I wrestled the transmission onto my floor jack, got it into relative position and attempted to align the input shaft with the clutch etc.
No matter how I tried, the top of the transmission catches the tunnel before I can get the transmission high enough for the input shaft to enter the clutch. I messed around with it for an hour or more. I am going to get another floor jack tomorrow. With the addition floor jack, I am going to loosen the motor mounts, using the foor jack to support motor and hopefully get the motor to tilt back far enough for me to align the transmission and bolt them together. What a mess. It will probably be late tomorrow night or Tuesday before I can work on it again. Time is running short.
May 4th, 2013
Nothing dramatic this morning, only had an hour to work on it. Made sure the transmission was cleaned out and filled it with liquid gold, aka Ford Fully Synthetic Manual Transmission Fluid. 1.25L
All ready for install
All ready for install
May 3rd, 2013
Well, I had a couple of Oh Sh*t moments tonight. the first one was when I took the top cover off to fill the transmission with fluid. This is what I found inside it.
I talked to Jeff and after he asked a few people, we hope it is a combination of ATF and gear lube. It looks non-friendly to my untrained eyes. Jeff recommended brake cleaner as a solvent and clean the stuff out of the case. I used 1 3/4 cans this evening. It looks much better. I drained it all out and am letting it sit overnight to dry out. I will check it again in the morning and clean again if necessary.
The second moment of the night was when I discovered a couple of chips on two gears. One is the on the reverse idle gear and the other one is on the input gear at the front of the transmission rail.
I assume (and hope) that an occasional nick is common and it won't effect the operation of the transmission. I am a little more worried about the liquid that came out of the transmission than anything else right now.
Hopefully tomorrow will be better
I talked to Jeff and after he asked a few people, we hope it is a combination of ATF and gear lube. It looks non-friendly to my untrained eyes. Jeff recommended brake cleaner as a solvent and clean the stuff out of the case. I used 1 3/4 cans this evening. It looks much better. I drained it all out and am letting it sit overnight to dry out. I will check it again in the morning and clean again if necessary.
The second moment of the night was when I discovered a couple of chips on two gears. One is the on the reverse idle gear and the other one is on the input gear at the front of the transmission rail.
I assume (and hope) that an occasional nick is common and it won't effect the operation of the transmission. I am a little more worried about the liquid that came out of the transmission than anything else right now.
Hopefully tomorrow will be better
May 2nd, 2013
Got the clutch fork boot today from the UK. Looks like it is going to work. I have included some pictures of the original one alongside the replacement. Not exactly the same shape on top, but the same dimensions on the bottom, so I think it will work fine.
May 1st, 2013
Clutch fork bushing/space issue solved. Made a trip to the Ace Hardware store and found a couple of options for replacement.
I used the one that was on the left. It was a little shorter than the original, but it had the correct I.D. and the pin is just tapped into the case, so I was able to adjust for the 1/32" shortness.
More progress, shifter is finally out. That was a pain!
I had to take both front seats loose so I could remove a couple of screws that were holding the console in. No fun at all.
Got the pedal box removed last night. Not too hard, but did take some time.
The one hiccup I did have, is that I discovered the clutch quadrant had broken at the tab that holds the return spring and the spring was MIA. The incredible Jeff Herson already has a new kit on the way.
I am just waiting on the clutch fork boot to show up from the UK, and with that and the quadrant, I may have this all back together by Sunday! Fingers Crossed
I used the one that was on the left. It was a little shorter than the original, but it had the correct I.D. and the pin is just tapped into the case, so I was able to adjust for the 1/32" shortness.
More progress, shifter is finally out. That was a pain!
I had to take both front seats loose so I could remove a couple of screws that were holding the console in. No fun at all.
Got the pedal box removed last night. Not too hard, but did take some time.
The one hiccup I did have, is that I discovered the clutch quadrant had broken at the tab that holds the return spring and the spring was MIA. The incredible Jeff Herson already has a new kit on the way.
I am just waiting on the clutch fork boot to show up from the UK, and with that and the quadrant, I may have this all back together by Sunday! Fingers Crossed
April 28th, 2013
Made progress over the weekend, and had one set back.
Progress: Took the flywheel to a machine shop to resurface it. Always a good idea, the flywheel was slightly warped. Looks much better now.
Installed the pilot bearing and the flywheel on Saturday.
Installed the clutch and pressure plate today.
I have to say, I like this much better than working on the A4LD.
The one setback of the weekend. The Clutch fork pivot bushing gave up the ghost when I removed the clutch fork.
Should have this attached on the shaft.
I pulled the piece out. I am hopeful I can find a suitable bushing to replace the one that failed.
Progress: Took the flywheel to a machine shop to resurface it. Always a good idea, the flywheel was slightly warped. Looks much better now.
Installed the pilot bearing and the flywheel on Saturday.
Installed the clutch and pressure plate today.
I have to say, I like this much better than working on the A4LD.
The one setback of the weekend. The Clutch fork pivot bushing gave up the ghost when I removed the clutch fork.
Should have this attached on the shaft.
I pulled the piece out. I am hopeful I can find a suitable bushing to replace the one that failed.
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