sutyak's turbo 2004 Mach 1 build thread

[wick]

I bet you cracked the blocker ring when you put it back together.

[sutyak]

I pulled the trans apart today and it's not pretty. It appears 2nd gear was in a bind with the cluster shaft. It turned by hand, but it certainly didn't like turning at normal RPMs.
After just 200 miles the 2nd gear synchro is completely toast, 2nd gear melted from friction against the 2-3 spacer, and cluster shaft teeth at 2nd gear are worn to the point of breaking. So not a great day.
I reached out to Stan at Pro Performance for assistance in a more definitive diagnosis. I'll keep everyone posted.
I do have a spare TR3650, but need to swap in a 26 spline input shaft, and just a general overhaul. I'm not sure if I'll rebuild the spare one first or figure out what to do with the GeForce gear set trans.

Cluster shaft on left with tips breaking off. 2nd gear on right. You can see the actual contact point is very small.


2nd synchro


2nd gear melted

[Cam99]

ouch. That sucks man

[somethingclever]

Sorry to see Mark.....

[PaxtonShelby]

Jeesh - that's a bummer. Why do cars enjoy kicking us square in the balls all the time...

[Martin0660]

I told you I would of had it back on the bench that night. Nothing that sounds like that fixes itself.

Believe me that is, and was, from experience. With these things if you suspect something isn't right, it isn't.

[sutyak]

I told you I would of had it back on the bench that night. Nothing that sounds like that fixes itself.

Believe me that is, and was, from experience. With these things if you suspect something isn't right, it isn't.

If I had pulled it immediately I don't think there would have been signs of wear yet and I would have possibly just reinstalled it and experienced the same frustration twice. 5-10 miles would have probably given me some insight.

[sutyak]

Sending parts to Stan at Pro-Performance, and then he'll likely send on to G-Force. No solid answer yet on what went wrong.
I'm going to install a 26-spline input shaft and do a general rebuild on my spare trans so I can get the car back on the road. I figure the trans with mostly stock parts will only be good for 500-600hp instead of 1,000hp. I still have a goal of getting to the track this year, even if it's on a lower boost setting.

[Cam99]

I admire your gumption sir. I'd probably be ready for a break from it by now. lol

[sutyak]

I admire your gumption sir. I'd probably be ready for a break from it by now. lol

Believe me, I'm ready for a break. I just want the car on the road so I can relax over the winter and not be stressed about car stuff. Maybe waste some time in front of the Xbox One for a while.

[Cam99]

lol, youre going to run even if it kills me!! I plan on puttering around with mine over winter, but it is hard to fight the urge to just get it all the way I want it right now instead of drawing it out.

[sutyak]

Car is back together with the spare trans and running great. Well it was until my clutch cable broke. Thankfully I was just backing into the garage. New Ford cable on order.
The G-Force parts are in the hands of Stan at Pro-Force Performance. We're all a bit puzzled at the moment as to exactly what was causing the binding of 2nd gear. Everything was assembled properly. I assembled this spare trans exactly the same as the other one, except mostly stock parts, and it's great. I'll let everyone know if they determine the cause.
Current trans has an upgraded 1-2 fork (not billet) with bronze pads, 26-spline input shaft, and replaced all blocker rings. I had to use the stock length aluminum driveshaft.

New plate


An absurd design for a switch. This is the reverse switch, which uses a thin diaphragm as an insulator between the plunger and electrodes. When this diaphragm wears out (and it will!), every time the car is put into reverse it will ground out and blow a fuse.


An upgrade that only I'll ever notice. I replaced the faux leather boots with real leather boots from an 03/04 Cobra.

[Monkeygrits]

That's my next move. New boots. My ebrake boot is ripped all to hell. I was thinking redline tuning. Did all the 03/04 cobras besides the anniversary come with real leather boots?

[sutyak]

I believe the anniversary was a carbon fiber looking design, but otherwise yes they were leather. Tough to find the ebrake not slightly ripped. This one my wife had to re-stitch the cloth part and patched a very small rip from the backside.

[sutyak]

Great news from Stan at Pro-Force Performance. He says G-Force checked out the parts and determined the 2nd gear section of the cluster shaft wasn't machined to spec, and was indeed in a bind with 2nd gear. G-Force is replacing all damaged parts. A huge thanks to Stan for his amazing customer support, and G-Force for standing behind their products. I'll reassemble the trans as soon as I get the parts, but not sure how quickly I'll get the trans in.

Overall the car is running great. It occasionally throws a code for a low RPM misfire, so I picked up some spare coils that I haven't installed yet. For typical driving I have the boost controller turned off and it's running off the wastegate at around 9psi. There are two wastegate settings, which are 50% and 100%. 100% is 18psi, and produces absurd wheel spin. I figure 50% is around 13psi but haven't played with it. Technically I'm still in the clutch break-in period, so I'm not going crazy.

[Ares]

Wow that's good news regarding the trans.

[sutyak]

G-Force Transmissions and Stan at Pro-Force Performance really came through for me. New trans parts are hear and the countershaft is polished and gorgeous! I'll get to work on reassembly asap, and hopefully get the trans installed early January after the holiday travel.
All told they replaced the counter shaft, second gear and synchros for second, needle bearing, thrust bearing, and provided new first and reverse. Only cost to me was shipping parts and fluid.

[sutyak]

With the weather being so nice this winter, I had the chance to take my Mach on a road trip. Overall it's running great. I've left it on the low boost setting for now until the clutch is fully broken in, but it's still a beast on 9psi. I took my 8 year old son with me, and it made me more aware of the gear whine and drive train noise resonance. The gear whine, resonating through the solid upper control arms, is pretty loud. I removed quite a bit of sound deadening material to weld in supports, but I'll add some back in to help limit that.
With the 4.10's and some playing around a bit in boost it got 19mpg. When I get the G-Force trans back it, my 5th gear will be .58:1 instead of .68:1, which is much better with the 4.10's.


The Corbeau GS II seats aren't as comfortable as stock. I really wish the lat and shoulder area was about 1" wider. I'm hoping they continue to break in and conform to my shape.
















So much for no rain the forecast.

[TooFast98Cobra]

Just thinking out loud.. wonder if u could get that filter into the wheel well and to me that is a ton of gear for a turbo deal. Other then that love this build.

[sutyak]

Just thinking out loud.. wonder if u could get that filter into the wheel well and to me that is a ton of gear for a turbo deal. Other then that love this build.

I'd like to get the filter into the wheel well, but the intercooler piping runs right there. I'm looking at significant pipe rework to get that to work, and then likely have to tinker with the tune because the MAF section is right there.



The 4.10's are definitely a bit much for the stock trans gearing and tire height. In post 172 I explained how the 4.10's and 28" tire will be like a 3.27 with the G-Force gearing, at least until I get into 4th.
I'm also assuming the turbo will continue to make power until 7K RPM with this gear choice. At the end of they day it's all just a calculated place to start. If I don't like it, I still have a 3.55 and 3.90 on the shelf.