240sx to 500sx conversion (5.0 H.O. swap in progress)

No updates yet, part that was supposed to show up, didn't show up, should be here tomorrow, which will mean I finally will have progress on the car again. Im shooting to have the clutch pedal, master cylinder, and trans tunnel hammered in by Tuesday.

I'm having to do alot more work, because this car was a non-abused Automatic, so I have to add a clutch pedal, and stuff to it. Its semi-easy because Nissan used the same firewalls for the auto and manuals, they just didn't drill the holes for the clutch assembly to mount up.

Ok small update, finally wasn't sick, didn't have the kids, and had some motivation to work on the car....

I got the new Energy Suspension poly steering rack bushings put in..... what a pain.... Also got the dash removed so that I can get the Clutch master cylinder installed, and pulled the factory cluster, since it will be replaced with a load of gauges..... much easier than modifying a Mustang cluster to fit in the factory hole.

Only have one picture, which my brother snapped of me, while I was under the car cranking on the steering rack

http://i57.photobucket.com/albums/g2...64212868_n.jpg


Gonna work on it again tonight, and hopefully get to installing the motor by Friday if I can....

cant wait to see pics of the motor down in the car.

Glad to see your making progress.... I am with pugsley i cant wait to see the pics of the engine in that car... That will be a fun street toy

I've had S-10's and Rangers with v8's in them and had an absolute blast with them. I've always wanted an import car with a lumpy ass v8 in it, so I'm enjoying the hell outta this thread. Cant wait to see the finished product!

looking forward to see this thing running... its kinda like a monster miata but cooler cause its not a miata.

Nice build u r deffintly on a mission

Finally got the engine hoist over to my house, and got the transmission off.... figures, one of the starter bolts was rounded off, so I had to cut the head off and pull the bolt out the hard way....

http://i57.photobucket.com/albums/g2...6059469742.jpg

The transmission could use some cleaning in here lol... Its ready to be disassembled so the hydraulic stuff can go on

http://i57.photobucket.com/albums/g2...6059486933.jpg

My guess is, this is what is left of the clutch disk.... and misc debris, though it cant be from outside, because the transmission was sealed to the motor quite well....

http://i57.photobucket.com/albums/g2...6059498757.jpg

Saving space in the garage for the night, the motor is sitting in the bay... its still off about 1 1/2" from its final position, but I still have to get the clutch off and removed, as well as get some bolts to stick in the header bolt holes so that I can drop the motor in the right way...
http://i57.photobucket.com/albums/g2...6059556875.jpg

Shows how it is sitting without the transmission on the back, and a little high.... there is so much room around the motor, I am really surprised how small this motor looks in the car.

http://i57.photobucket.com/albums/g2...6059541247.jpg


I kinda cracked the starter flange (where the upper bolt goes) when the starter wouldn't come out, seems it was seized in there pretty good, dunno why though, it works fine.... Are they pretty cheap? Should I replace it, or should I try fixing it?

Sorry for the lack of progress in the last couple weeks/month I have been slacking quite a bit.

The motor is not in its final position, because I am going to order a new clutch and then reassemble everything.

Ordered my King Cobra Clutch kit for it tonight.... looks like I will be able to put this thing back together very very soon..... All that's left is...
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1. Install clutch kit
2. Install Hydro T/O bearing
3. re-mount transmission on engine
4. Install engine and transmission
5. Make adapter for shifter relocation
6. Wire up motor to 240sx body harness
7. Install gauge setup (still pending on if the ARK MFD will work with this motor)
8. Measure and have driveshaft made
9. Buy radiator and mount
10. Put fluids in, and drive.
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Still alot left to do, not including putting a cage, and racing seats/harnesses in.... As well as taking the bald rear tires off and having more tires put on.

Radiator and clutch arrived....

All aluminum Radiator
http://i57.photobucket.com/albums/g2...7517071702.jpg

King Cobra Clutch with new pilot bearing, throwout bearing (don't need it)

http://i57.photobucket.com/albums/g2...7517124570.jpg

I am getting excited :D

Gonna have some major updates later tonight... I am currently working out how to install the RAM hydro throw out bearing, since my King cobra clutch pressure plate is touching the C clips, I guess I have to remove them, and then get my spacing right, and all will be done.

The motor is just a few minor steps from getting permanently mounted in the car.

looks good man, keep us posted with pics.

man that looks like one hell of a tight fit

here's some pics I snapped, my brother took most of the pictures, so I don't have all of them yet, but this is what I have.

I put a new rear main seal, and pilot bearing in. Didn't take pictures, didn't seem important enough to

I knew I needed a new clutch, the previous one was toast.... Here's what the flywheel looked like when I pulled it off.

http://i57.photobucket.com/albums/g2...8219110260.jpg

So I sent that off to get re-surfaced, because there was no way I was going to get away with fixing it myself....

Took it to Auto Value here in Wilmington and here is the result

http://i57.photobucket.com/albums/g2...8219162639.jpg

After a nice cleaning with brake parts cleaner, I installed the King Cobra clutch, and pressure plate. Everything went together pretty easily, and looks good installed.

http://i57.photobucket.com/albums/g2...8219400895.jpg

After all that fun stuff, I got started on the hydraulic throw out bearing. Its made by RAM clutches, and seems to be pretty solid. It was kinda pricey, but for a swap like this, it was necessary, as the 240sx is hydraulic to begin with, and swapping to a cable would require a different clutch pedal.

After removing the old clutch fork, and throwout bearing, then removing the pivot ball, and original center section (don't know what its called) I installed the RAM center section, that is made for the hydraulic T/O bearing to slide on, and putt the hydraulic bearing on there for measurements.

http://i57.photobucket.com/albums/g2...8219517980.jpg

This is what it looks like through the old clutch fork hole.

http://i57.photobucket.com/albums/g2...8219436340.jpg

All in all, it went pretty easy, though I have to talk to tech support with the bearing, because the instructions say to get the clearance down to .150-.200" and I am at .500" . Obviously I need to use some shims, but I want to make sure that I am doing everything 100% right. The other small issue, is the fact that the bearings C clip hits my pressure plate fingers, which means I am going to have to remove them, in order for it to work properly.

After I get this done - Possibly by tomorrow - The motor will be getting mounted into the car and the next step of the process will begin.

On a positive note, I did look up the transmission code, and it is a 1992 WC T5....

Quote:

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Originally Posted by blown96cobra

man that looks like one hell of a tight fit

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believe it or not, it actually doesn't look all that bad when your looking at it in person.... If your ever in Wilmington and wanna stop by and look for yourself, just shoot me a P.M. It always helps to have a mustang guy there to tell me what I am doing wrong :lol:

That oil filter looks really close to that frame rail!! Lol

Quote:

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Originally Posted by Stangman

That oil filter looks really close to that frame rail!! Lol

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I think I am going to do a relocation kit on it.... your right in a sense, even though there is enough room to get it off, it sits a little too close to make me happy... I am going to get the engine in its final location, bolted up, and see if it is better or worse.... If it doesn't improve, I will be ordering more parts... :mad:

a couple more pictures from today, got em from my brother, who stayed clean through this whole ordeal lol....

http://i57.photobucket.com/albums/g2...u/76f45c4f.jpg

http://i57.photobucket.com/albums/g2...u/4b3b18ec.jpg

http://i57.photobucket.com/albums/g2...u/182562f8.jpg

just a few pictures of putting the Hydraulic T/O bearing on.... way more in depth than I originally thought.... the old sleeve held the race, which had to be removed, and relocated to the new sleeve, seemed the transmission is in pretty good shape.

we got some pics setty.lol

cool build,good luck with it

Well my power steering bracket showed up today, waiting on a replacement radiator, since the one I ordered was measured without the end tanks, and didn't fit at all. New one is well within size requirements, and is actually a 2 core, so all I have to do is run a longer hose from the lower pipe to the right side of the car instead of the left, and all will be well

Curious to see how that hydraulic setup works out for you.

Looking good!!! did that driveshaft and pullys work out for ya??

The driveshaft is going to work out great, I haven't gotten the measurement I need to cut it yet, but as soon as the motor goes in, I will send it off to the shop to get done.

I've been doing the last couple month's of this build from unemployment, since I was laid off in November, so my money has been short.... almost to the point where I considered selling it off.... But I have too many people telling me I won't finish the car to give up now... especially since its very close to being done.

I have heard very good things from another guy in California, that runs this setup on his 240sx, and all of his customer cars, so I have high expectations as to how its going to work.

well I was pretty much ready to drop the motor in the car and ran into this problem... using the shims that I calculated based on the measurements they told me to take... the C clip hits the pressure plate fingers. Talking to Ram Clutches (T/O bearing designer) they say to remove the C Clip... Talking to the guy who has done this swap 10+ times now, he says there is no need to remove the C clip, that I just remove shims til it fits... So that is what I am going to do I guess... may require me to pull the motor once or twice, but at least it will be exactly the way I need it to be...

http://i57.photobucket.com/albums/g2...1955140968.jpg

http://i57.photobucket.com/albums/g2...75137687_n.jpg

Motor is in the car. I had to cut out a new shifter hole location as the T-5 is shorter than the stock transmission. I am currently in need of a few more parts.....

I need

Alternator harness - I dont have one

Power steering bracket - The ebay model doesn't line my pump up at all...

AND lastly, I need someone that lives in Wilmington to drop by and tell me what some things are. There are a few things that I have that I have never seen and would like to know what they are and if I need them.

Since I forgot to post it on here.... I just had to take that c clip off the t/o bearing and it fit great. I haven't bled the system yet, still waiting on getting everything together before doing that. The hydraulic setup looks factory now, really easy to do.

where did u get your king cobra clutch? I believe i checked ford racing a few months back and it was no longer available

I ordered mine from CJ pony parts. They had some listed on ebay, and I got mine quite a few month ago.... This project has been taking me a lot longer than planned since halfway through it, I lost my job, had to move due to renovations, and lots of other random garbage hit.

Well I picked up a FRP power steering bracket and pump off of 93hulk last night, went to drive home, and my daily decided it didnt want to drink coolant anymore.... Started spitting it everywhere. Car overheated (nowhere to pull off in time) and shut off. Oil light, and check engine light came on.... Waited 30 minutes started the car up and it sounded like something was wrong.... 47k miles.... GM is going to fix it under warranty, but it makes me not want to buy GM cars anymore.

cool build, good luck with it!

Thanks, I might actually get to work on it this weekend. Seems the daily has a Power steering leak (ironic since I picked up a PS pump for this car) and caused the radiator hose to soften/split.... Once I get that fixed, I will get back to work on this car.

Anyone know the size and pitch of the water pump pulley bolts?

Quote:

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Originally Posted by 89johnny

Great project dude. Ive had four 240sx's three with ka and one with sr20 and my gently modded 5.0 mustang would beat all of them. So imagine how the 240 would run with a 5.0 in it! I was always interested in this swap and im dying to see how it turns out. Keep us posted man

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I am working on it, still need some guys to come over and help me out with a few things one night.... Would be helpful to have someone that knows mustangs around.

Just a quick update on where I am with this.

I took the water pump off, and am replacing it, broke a bolt, had to take the timing cover off (what a PITA)..... As soon as I get that done, I can start putting the car the rest of the way together, and maybe, just maybe, get it started in the next month or two.

Ok so some real updates for once....

I got my brand new water pump, found the bolts that hold the pulley on (5/16 -24 pitch in case your wondering.... no fan = less than 1/2" bolts)

I put a couple new bolts in the timing cover, put the front oil seal on, and got it all looking good.

I put the radiator in for the first time, just to test fit it.... hoses are going to be fun for sure.

http://i57.photobucket.com/albums/g2...2586925103.jpg

I took a picture of my shifter location.... Its a little forward from stock location, but not too hateful.

http://i57.photobucket.com/albums/g2...2586943656.jpg

I still have to get the right bolts for my Ford Racing power steering bracket, which I also noticed, the previous owner of this engine, took one of the alternator bracket bolts out for some reason.... so now I gotta buy 3 .

I've wanted to put one in a coupe. One day I will.

Keep us updated can't wait to see it run

I'm currently trying to find someone that will make me a set of headers "cheapish" . The steering shaft is holding me back. If anyone knows someone that can do it reasonably, let me know.

Well my wiring harness is at a shop in California getting re-built to be much simpler and easier to run. The company is Concept-8 http://concept-8.com/services.html.

For less than $200 he will take your harness, and strip all un-needed stuff out, label all necessary wires, and label what wires go to what gauge if you wanna run different gauges. I'll post pictures when I get mine back.