Ive been trying to give Bill some info on his mod swap so i started typing this.....Ill clean it up add some pictures. Add some info if you have some or help clear up any mis-information.......This swap thread pertains to N/A cars using a mark viii donor.
Brakes
A hydroboost from a 96-04 car is needed. Make sure if it doesn't have lines, you get the lines for the year of hydroboost you are using, they are different in some years!
The holes will need clearanced on the body, it has a slightly different pattern than the stock vacuum booster. The hole where the rod goes through is egg shaped instead of round and will need cut. You will also need a pedal assembly from a 96-04 hydroboost car. The rod hits the pedal at a different angle. The pedal assembly then needs modified to bolt to the H bracket that supports the steering column. Cut a portion of the fox pedal assembly off and weld it to the sn95 assembly.
Line will need cut and re-flared with new nuts to match the thread in the master cylinder.....gut the proportioning valve and get an adjustable.
you could also go manual brakes if you wanted and ditch the vacuum booster.
K member
You will need either an aftermarket K member or a 96-04 K member. ANY 96-04 car will work v6 or v8. It will need to be modified to fit in for chassis. Here is a rough estimate of how to relocate the bolt holes on the rear mount of the K member. The mount also needs trimmed, the edge of the cardboard in the picture is approximately where it should be trimmed.
Use 96+ spindles for correct bumpsteer with stock 96-04 K member or whichever are recommended by the manufacturer of your K member. Use the motor mounts from a 96-04 mustang. You may need a longer steering shaft, it is very close to not reaching. The steering rack mounts lower on the K member in modular cars hence the steering shaft length issue. Clearance on the DS manifold is close to the shaft so check. There is a bolt and nut that may hit on it. If it does you will need a shallower bolt/nut or a aftermarket shaft. Using an aftermarket K-member/steering shaft is a good idea to free up header room, and if you do, Cobra or 4.6 model headers will work although number 7 will have to be dented/pinched pretty good to clear. Best would be to modify/reweld #7, still much cheaper than custom headers.
Engine and Accessories
You can use the timing cover from a mark viii/cobra and the power steering pump+reservoir. Use corresponding tensioners/idlers for your timing cover. The timing cover from the mark viii is able to bolt either coil pack brackets OR the bracket that holds the power steering reservoir on COP cars. Alternators from any DOHC mark/mustang will work. Starter will work from any mark or V8 mustang. valve covers just matter if you plan on going COP or coil pack they work on C and B heads.
the oil filter/coolant neck will also work from the mark, its possible oil pan will work too but i just bought a 96-04 pan because the mark has the huge reservoir on the side of it. you can use the thermostat housing from the mark viii or get one from a DOHC mustang. Note SOHC cars have the thermostat in the intake so don't bother looking for a housing from one! You need to get a cap for your radiator that doesn't allow flow out of the normal overflow on the rad. Instead run a overflow tank from your thermostat housing. All the coolant cross overs are practically the same minus the mounting brackets so decide if you want to weld the brackets or just buy the one that's correct for the intake you plan to use.
If you intend to stay with B heads you will need a 98 mark intake+IMRC (its looks like this http://www.thedetailzone.com/Cort2.JPG) OR a 96-98 cobra intake and the IMRC plates. your IMRC plates from the earlier mark will not work. You will also need the supporting pieces from the intake (TB, Throttle cable from a 96-98 cobra) You can also buy IMRC delete plates or make them by removing the butterflies and sealing the holes.
If you want to go 99-04 C heads you will need the intake from a 99-01 cobra or 03-04 mach. no IMRC plates are needed for this intake. If you use this get a 99-01 or 03-04 cobra/mach throttle cable. TBs are different for C and B headed intakes, use correspondingly.
Fuel system
get a set of 96-97 cobra fuel rails no matter what intake you use you will need them for the return system on the fox. they will have to be modified for the C head (99-04) intake but its easy. The mounts on the rails will need cut and re-welded to hit the mounting bosses on the 99-04 intake. Do yourself a favor and make sure there is no gas hanging out in the rails. The two crossover lines need to be cut off and high pressure fuel hose clamped in place of them. The 99-04 intake is wider and the cross over int long enough to span the intake. The rails also require a little bend right where the cross over attaches so the dont hit the intake. avoid 98s they have a different style. Aftermarket rails are always an option as well. Match your fuel pump for your horsepower needs.
Wiring
Wiring can be used from any 96-97 V8 car, if you delete the IMRCS or use C heads you can use a GT wiring harness and computer. If you want to keep the IMRCs you will need a 96-97 cobra harness/computer and the IMRC box.
ALL computers will require a tune, the PATs system must be disabled or it will not run. Tune for injectors if you are using a GT harness/comp.
I recommend getting the entire body harness from a donor car.A website called http://www.thedetailzone.com/ makes a harness for the swap to control the engine using the factory computer/sensors at a cost of about $600-700.
If you use the entire harness you will have to do these things:
-Match your gauge/headlight switch/four way wires using your fox plugs to the SN95 body harness.
-Wire your power windows and locks to the SN95 harness
-Wire the fuel pump
-Wire the brake lights and turn signals, if you use LX tails this is easy....if you intend on using cobras or older GTs this can be a pain. The newer car flashes the brake lights for the turn signal. Take the third brake light wire and use it for your brake lights. If you have a amber bulb in your taillight use the normal brake/turnsignal wire for it. You will need to disconnect the brake light wire from the flasher under the dash so the amber doesn't come on with the brake lights.
-headlight plugs for both sn95 and fox are the same but are pinned out differently, move the wires in the plug to fix the problem
-wire the parking lights
-use the mark viii cooling fan, it plugs directly into the 96-97 harness make brackets to fasten it to the rad.
-wire the rear hatch for the trunk release, defroster if you want it and the third brake light in the hatch.
Luckily most of the wire color coding is the same for both cars which eliminates some of the guess work.
I have wiring schematics for both cars contact me for them.
Driveline
If you want to use a t-5 tranny get a quick time bell housing intended for a tremec, they have the same input shaft length. Drill your holes and bolt up. a clutch kit for a t-45 or t-56 car will work for the t-5. Take notice number of splines the clutch is made for when ordering. Pilot bearing is also the same size for all of these trannys. stock drive shaft length will work. Also make a note earlier 4.6 flywheels have patterns for 10.5 and 11 inch clutches newer ones just have provisions for 11 inch.
heres the mounting difference between the tremec and t-5(black marks are where the t-5 holes should be drilled)
Its not as easy to use the aluminum bell, material needs to be welded to the bell so you have enough to thread into....there are no bosses cast in the t-5 bolt locations
If you want to use a t-56, t-45 or a tr3650 from a modular car you will need to weld a trans mount from a newer 96-04 car on to your floor boards or buy a mount intended for this swap. You will also need a shortened drive shaft.
Exhaust
stock manifolds will work for this swap.
I cant give you a list of which long tubes will and will not work. Use a X or H pipe for a 96-04 DOHC mustang when using stock manifolds. stock fox catback will work fine. Some clearancing may be needed on the trans mount if you are using the stock fox mount with the t-5.
Reply With Quote
Bookmarks