North American Turbocoupe Organization



4.6 Modular Swap into my 87
deadbird Offline
Posting Freak
#1
Pictures of the swap here!
http://s1318.photobucket.com/user/kilo7788/library/Swap

Swap/Project Pegasus(Horse-Bird)

I had a 87 Turbocoupe was having running issues and had started leaking from practically every seal. The motor needed to be pulled to fix it. I listed it for sale and had purchased a 02 Mustang GT that needed rear tires. On the day I went to get tires it was raining and the rear end sung out on a freshly paved off ramp and hit a guardrail. The insurance company totaled the car and I chose to keep the remains.



I am not a mechanic and have never done a major build before. My experience is limited to bolt-ons and I replaced a motor and trans in a F-350 before. I stripped the car to a carcass scrapped it and began to sell parts. I also started looking into swapping the drivetrain into my Thunderbird and I found the website modularfoxmustangs.com. The main problem was looking at was the cost. I would have to complete the swap spending no more money than I could raise by selling parts I did not need from the Mustang and the Thunderbird.

COST

Having a complete donor car saved a lot of money and provided money. I was able to complete the build within budget and I got extras as well. The interchangeability of Tbird/Foxbody parts and SN-95 was a big help. Major items were the transmission cross-member, tuner, exhaust, incidentals and upgrades.



The trans cross-member I was able to get used and it came with and offset mount. I am not sure on the mount but the cross-member was Stifflers. The tuner I went with was the Sniper system with Special Forces software. I went with a Pypes off road H pipe.

I was warned at the beginning of the project that costs quickly escalate when to upgrade parts. The Programmed Ride Control system in the Thunderbird was tired and I replaced it with KYB Gas-a-Just shocks and struts. I also went with Maximum Motorsports Caster/Camber plates and used the Mustang springs to lower the Thunderbird.

Other additions were an AC delete pulley and underdrive pulleys. The possibilities are endless and very tempting because of their ease with everything apart. Heads, intakes, forced induction the list goes on. Since the car is old I cleaned and rust I found and repainted. The inner fenders and nooks and crannies were painted with truckbed liner.


THE SWAP

I did not have air tools or a welder. The welding was done by my neighbor who is a Junior in a high school metals tech program. Yes there was extra effort put in however I was trying to make every dollar stretch as far as it would go.

FRAME/SUPPORT

I modified the Mustang cross-member to use in the Thunderbird. All that was required was to cut a little over and inch from the back of the bottom mounts and drill new holes into the flat part. Also when cutting the bit off of the end I slit farther back and flattened our more to get both holes out.

I used the larger bolts on the upper mounts. I re purposed them from the a-arm mounts that were no longer being used and put a ¼ inch spacer in between the cross-member and the frame. I never took the motor and transmission off of the cross-member. I simply picked the Mustang up and dropped the Thunderbird on top of it. It did take several times to get it perfect. (trimming metal). I did have to put the H pipe on the manifolds before putting the engine in. It is a very tight fit.

On the passenger side the extra lip from the frame and cross-member had to be trimmed down. I have approximately ¼ inch of clearance there and 1 inch between the passenger side head and the strut tower.



CONTROLS/BRAKES

I used the mustang pedals and combined them with the Thunderbird parts to work with the steering column supports. The Thunderbird has a hydraulic clutch and the Mustang did not which prompted the swap. I also swapped the hydro-boost brake/power steering system in to alow more room in the engine bay as the Thunderbird master cylinder was much too large.

DRIVESHAFT

I replaced the U-joints and put the Mustang transmission shaft on the Thunderbird driveshaft and it fit perfect.

STEERING

I used the Mustang hydro-boost system and steering rack. I modified the Thunderbird steering shaft to fit on the Mustang steering rack. They were both the same length and I separated them and reconnected them at the rubber.

FUEL

I wanted to use the Mustang tank to make it simpler. I eliminated the evap system and cut a section of the trunk floor pan to make it fit under the car. I ran all new fuel lines and re-used the Mustang lines to the fuel filter that I relocated to just in front of the trunk pan. From there I spliced in the new line from there.

The first thing I took apart on the Mustang was the fuel tank. I had not planned on doing the swap and had a full tank of fuel I wanted back and I wound up cutting the fill tube. I reduced the Thunderbird fuel fill neck size to fit the Mustang tank.


ELECTRICAL

By far the most daunting part of the swap. I did have a wiring manual specific to the 02 Mustang GT and I had the Chiltons for the Mustang and Thunderbird.

When I took the wiring out of the Mustang I did not cut anything. I placed it on the garage flood and reconnected the entire thing including the sensors, instrument cluster. The connectors that went to the motor I marked with tape.

I eliminated all of the chassis wiring, (speakers, seats, abs, cruise control) I then singled out the keyed power and prepped those connections to be added the the Thunderbird's keyed power. I also found the start wire attached it to the Thunderbird start wire. I retained the Mustang power distribution box ander installed it near the battery. I ran the Thunderbird main power off of the box as well. This also gives me future wiring options. I retained the Thunderbird fuse box in the dash and eliminated the ABS, and PRC wires and their computers.

I wired the brake light wires to the Mustang brake light switch.
I taped the Mustang key to the PATS sensor and hid it in the dash. This was not completely needed as I turned PATS off with the tuner.

I modified the Thunderbird dash for the Mustang instrument panel. I used a heat gun to melt the dash and form it to the Mustang instrument panel. I did have to cut the lower right tab off of the panel. I used a wire tester to figure out which wires were for the high beams and the indicators so they would work in the cluster.
1987 5 sp.
- 4.6 2v swap.
Reply

Ramos617 Offline
Member
#2
Wow sounds like quite the conversion
I would to see some pictures if you have any
1987 T-Bird
Too much stuff to list
Running better than ever
Reply

deadbird Offline
Posting Freak
#3
The pics are in the link.
1987 5 sp.
- 4.6 2v swap.
Reply

TurboCoupe50 Offline
Posting Freak
#4
GREAT WORK!!! Kickin' ass(butt isn't what I typed)...

I'm not a 4.6 fan but no doubt makes a nice driver, also gives the clueless a idea what is required for a major swap such as this...
1988 Turbo Coupe331 AOD

1972 Comet GT

1969 Fairlane Cobra 428CJ 4-Speed
Reply

deadbird Offline
Posting Freak
#5
It was fun and I learned a lot. I'm not a huge 2v fan but the opportunity kicks of dropped in my lap and they like BOOST! I wanted to run twin rear mount turbos but I don't have room. Don't have room for any extra turbo piping unless I dump the exhaust in the front. I'm probably going to have to supercharge it.
1987 5 sp.
- 4.6 2v swap.
Reply

TurboCoupe50 Offline
Posting Freak
#6
Slap a Eaton on top, ain't nuthin' prettier... Had one on a Marauder, couldn't say anything bad about it, just somehow we never became friends...

It had dynoed 430Hp at the rear wheels just before I bought it...

[Image: AS710%20240.jpg]
1988 Turbo Coupe331 AOD

1972 Comet GT

1969 Fairlane Cobra 428CJ 4-Speed
Reply

deadbird Offline
Posting Freak
#7
Mmmmm pretty.
1987 5 sp.
- 4.6 2v swap.
Reply

dardave Offline
Junior Member
#8
Ever had you car to the track? how fast is it?
Reply

deadbird Offline
Posting Freak
#9
The one day I took off to take it to the track. The track had to close because of construction
1987 5 sp.
- 4.6 2v swap.
Reply





Users browsing this thread:
1 Guest(s)



Theme © iAndrew 2018 - Software MyBB