S5 Convertible TII+Extras Swap Project (Pictures!)
 

Well I have been doing some work on my seven for the past few months. Now that the semester is over (yay, two more to go!), I want to share with you guys what i've been up to....

First, a picture of the before.... Your typical 91 S5 Vert.

http://i1006.photobucket.com/albums/...9/DSC00772.jpg

I found these old pictures from when i was in TX, good times.... Replaced the exhaust spring 09 with a RB header and magnaflow catback

http://i1006.photobucket.com/albums/...9/DSC00643.jpg

What is this!??? It scared the crap out of me when it came out! This was the most painful thing to remove, so many tiny awkwardly placed exhaust shield bolts + ACV!!!:

http://i1006.photobucket.com/albums/...9/DSC00663.jpg

More good times.... Driving to walmart, I smelled tons fuel! Actually, I smelled hints of fuel ever since I got this in fall 08. I thought it was your typical rotary, was I wrong, luckily I knew what too look for!

New Pulsation Dampener, with heat wrap!? I was very paranoid back then since I was going to be driving to MN in the summer...

http://i1006.photobucket.com/albums/...9/DSC00815.jpg

New Vacuum Hoses.... Look all the emissions stuff is still on there, ha!

http://i1006.photobucket.com/albums/...9/DSC00765.jpg

Wheel bearings get serviced up front for my trip back to MN!:

http://i1006.photobucket.com/albums/...9/DSC00805.jpg



Back in MN, Summer 09 emissions removed, I need simplicity!:

http://i1006.photobucket.com/albums/...9/DSC00815.jpg

Depowered the rack, removed all seals, had the holes TIG welded shut, I couldn't find the end result pictures, but here is one where it is getting worked on:

http://i1006.photobucket.com/albums/...9/DSC00820.jpg

Brake servicing while the car is up in the air:

http://i1006.photobucket.com/albums/...9/DSC00825.jpg

Everything back together, I think...

http://i1006.photobucket.com/albums/...9/DSC00834.jpg

Current Fall 09:

Then I found this!!! S5 TII JDM Trans!, Primed:

http://i1006.photobucket.com/albums/...9/DSC00863.jpg

Sprayed, with solid mounts:

http://i1006.photobucket.com/albums/...9/DSC00879.jpg

Thanks to Japan2LA, I got this now, S5 TII Diff. Mount is getting beat out of it in this picture. All done the old fashion way, hammer and punch.

http://i1006.photobucket.com/albums/...9/DSC00958.jpg

http://i1006.photobucket.com/albums/...9/DSC00957.jpg

Prepping:

http://i1006.photobucket.com/albums/...9/DSC00960.jpg

Primed:

http://i1006.photobucket.com/albums/...9/DSC00965.jpg

Sprayed, starter is in there too!

http://i1006.photobucket.com/albums/...9/DSC00976.jpg

Delrin Mounts, went in in 10 seconds with rubber mallet:

http://i1006.photobucket.com/albums/...9/DSC00979.jpg

Removing shifter for the old leaky N/A trans:

http://i1006.photobucket.com/albums/...9/DSC00991.jpg

Removing stuff off the old trans:

http://i1006.photobucket.com/albums/...9/DSC00995.jpg

Coming Out!:

http://i1006.photobucket.com/albums/...9/DSC00998.jpg

http://i1006.photobucket.com/albums/...9/DSC00999.jpg

http://i1006.photobucket.com/albums/...DSC01006-1.jpg

http://i1006.photobucket.com/albums/...9/DSC01005.jpg

Fellow club member picked it up from me. Hope it helps him win some races in NASA.

Now its freezing outside, around 0, I got more goodies but need to plan out what to do about this coldness. I will update when I get more pictures. The goal right now is to get this drivetrain in, engine rebuild, new suspension bushings. Then we will see what to do from there, once it drives again :nod:, I miss driving the car :(

clean car, so are you going to turbo the 6 port? I like how you painted that diff, I need to start doing stuff like that when I work on my car.

Thank you! Yes.... 6port+turbo, once it runs again though. I was hoping to do it all at once, but I figured rebuild engine, get it running again, megasquirt, then turbo...

looking good

That's a clean car to start with, and it looks like it's on it way to looking even better. It always seems when you start taking things apart, you find parts of the car to clean & paint. I'm the same way, and can't bear to put things back together dirty.

Thanks for all the comments, I hope it turns out good once I finish this up also!

I decided to work in the garage, regardless of the 12*F temperature. I got to finishing up the rebuilding of the TII half-shafts. The JDM axle boots were cracked and weathered so new ones went on, along with new moly grease :nod:

http://i1006.photobucket.com/albums/...9/DSC01009.jpg

Axles are always fun.... lots of grease everywhere:

http://i1006.photobucket.com/albums/...9/DSC01010.jpg

If anyone does this, don't even bother taking apart the side going into the spindle/hub, just clean it out well with parts cleaner:

http://i1006.photobucket.com/albums/...9/DSC01011.jpg

Make sure you clean your balls well:

http://i1006.photobucket.com/albums/...9/DSC01013.jpg

New boot going in (no grease applied yet, it would get all over the camera if I did):

http://i1006.photobucket.com/albums/...9/DSC01015.jpg

Finished products, I couldn't find my cutters to snip off the excess clamp (don't let friends borrow tools lol):

http://i1006.photobucket.com/albums/...9/DSC01018.jpg

More to come....

Nice , keep it going.

you got a wood stove in that garage? if not i'd look into gettin one. it'll be your best friend:)

That would be nice, but I did manage to find a propane heater, will be picking it up tomorrow, it should keep me warm :lol:

Well today I put the shipment of parts onto the S5 TII Transmission. My old N/A transmission had leaks everywhere (i think it just came mostly from the rear seal, which ended up getting splattered everywhere by the driveshaft) and a loose shifter. I want this transmission to be spotless and finally be able to drive without smelling gear oil all the time and have a firm shifter.

The parts:

http://i1006.photobucket.com/albums/...9/DSC01019.jpg

Started with the simplest, the new front diff mount. It's the mazdatrix competition mount, it is extremely light compared to the stock one, now the diff is finally ready to get put in:

http://i1006.photobucket.com/albums/...9/DSC01022.jpg

http://i1006.photobucket.com/albums/...9/DSC01023.jpg

http://i1006.photobucket.com/albums/...9/DSC01025.jpg

The transmission. I started by replacing the rear (output) seal:

http://i1006.photobucket.com/albums/...9/DSC01028.jpg

http://i1006.photobucket.com/albums/...9/DSC01030.jpg

http://i1006.photobucket.com/albums/...9/DSC01031.jpg

New seal in place:

http://i1006.photobucket.com/albums/...9/DSC01034.jpg

Now, the part I dreaded since i've read bad stories on here. Replacing the shifter return spring, along with the shifter "controller".

http://i1006.photobucket.com/albums/...9/DSC01035.jpg

Pay close attention to the orientation of this part:

http://i1006.photobucket.com/albums/...9/DSC01037.jpg

The competition front diff mount is lighter because it doesn't have the weight block. You can easily transfer the block onto the new mount. It's job is the cancel out some vibrations, and with those solid rear mounts, it'd probably be a good idea to keep it.

http://i1006.photobucket.com/albums/...9/DSC01038.jpg

Pushing out the roll pin, make sure to do it only at this angle or I think you might get the shifter controller stuck against the wall. You don't want that to happen:

http://i1006.photobucket.com/albums/...9/DSC01039.jpg

http://i1006.photobucket.com/albums/...9/DSC01040.jpg

Rotate the shifter rod inside that housing 180*. It will drop down, allowing you to remove everything (the rod is not rotated in the picture, it will drop down way more than this).

http://i1006.photobucket.com/albums/...9/DSC01042.jpg

Comparing the old parts with new:

http://i1006.photobucket.com/albums/...9/DSC01044.jpg

Going back in:

http://i1006.photobucket.com/albums/...9/DSC01045.jpg

Rotated the shifter rod, back into position to push roll pin through:

http://i1006.photobucket.com/albums/...9/DSC01049.jpg

Everything back together:

http://i1006.photobucket.com/albums/...9/DSC01050.jpg

Old Front seal and cover:

http://i1006.photobucket.com/albums/...9/DSC01051.jpg

Cover off:

http://i1006.photobucket.com/albums/...9/DSC01053.jpg

Seal off:

http://i1006.photobucket.com/albums/...9/DSC01054.jpg

Comparing old with new, notice the old one has wear on it, though it doesn't look to bad but I can imagine on higher mileage transmissions you would want to replace this when servicing the clutch:

http://i1006.photobucket.com/albums/...9/DSC01055.jpg

So then I started to put the new seal in place and got way too carried away with the hammer and ended up slightly denting the new seal. I don't want to risk any leaks so a new seal will be coming in soon.

Looks like the majority of the small things are done, waiting on bushings now for the DTSS, and front & rear control arms. More updates will follow...

good stuff :icon_tup:

Yeah I figured that's why it was light. Are there any negatives of running without the weight besides vibrations? I might go ahead and put the weight on....

Some more updates:

I started to take apart the rear subframe mounted components and stopped when all I need is to lower the subframe now:

http://i1006.photobucket.com/albums/...9/DSC01086.jpg

http://i1006.photobucket.com/albums/...9/DSC01061.jpg

http://i1006.photobucket.com/albums/...9/DSC01063.jpg

I also got my delrin bushings in for the rear suspension. I ran into a confusion/problem with the setup I was going with since I had ordered delrin rear control arm bushings. As you guys have seen, I will also be running delrin subframe, differential, and DTSS bushings. I found out that using those delrin control arm bushings will not allow me to adjust camber at all once I put everything back together if I get camber adjusters, so with a bit of research and help from some nice members here, I was able to get sorted out. If you are interested in what went on visit here:

https://www.rx7club.com/2nd-generation-specific-1986-1992-17/rear-subframe-bushings-spherical-arm-bearings-confused-879088/

Front control arms got sprayed (thanks 87-t66 for the arms):

http://i1006.photobucket.com/albums/...9/DSC01057.jpg

Delrin bushings will be going in on the front control arms soon....

I got a package today with some more goods. I've been wanting to swap these light housings in for a while. These are conversion housings from Hella that allow you to run H4 bulbs instead of replacing the whole housing. They have a really nice light output. Besides that, I got the bump stops (a.k.a. pinion snubber) for the rear differential once I put it in:

http://i1006.photobucket.com/albums/...9/DSC01065.jpg

Here are some pictures of the old housings I had. The old ones were Sylvania Silverstars:

http://i1006.photobucket.com/albums/...9/DSC01071.jpg

After shot with the new Hella Housings:

http://i1006.photobucket.com/albums/...9/DSC01080.jpg

Side by Side:

http://i1006.photobucket.com/albums/...9/DSC01076.jpg

Now, I was looking at the S5 UIM TII manifold I got a while back, I noticed it had no brackets at all! Now I need to figure out where to get the brackets for this. If anyone reading this can let me know what brackets I need it would be helpful, otherwise I might make a dedicated post for that....

http://i1006.photobucket.com/albums/...9/DSC01083.jpg

I know I need the throttle cable bracket, cruise control bracket and the one bracket with the hole in it to lift the engine with (i think that's what its for).... Anything else I might be missing, I couldn't see anything else in the FSM.

the other bracket to hold the inter cooler.

+100

good job ... looking good

hey nice build but what are the specs one the Headlights? I;m trying to do that myself this winter break

Thanks, I figured I might of missed something! I posted I wanted ad on the classifieds, I will need these down the road when I get to the engine....

:lol: Well I finally found a 35,000 BTU propane heater. Works like a charm so I can't complain about this coldness anymore, just have to motivate myself to work in this weather.

Thanks!

The headlights are Hella Vision Plus Conversion Lamps for H6054 Housings. They come with the adapter from the headlight harness to the H4/HB2/9003 Bulb, and they also include a really nice bulb with them. Summit had the best price:

http://www.summitracing.com/parts/HLA-003427291/

I just installed the comp mount in my car, and the weight block was transferred over. I know some others have left it off, but I figure it can't hurt to keep it. Best I can tell, harmonics are the only reason it's there in the first place.

These housings look very nice. I'll have to ask you later how well they work (or maybe you've tested them a little already?). I've been thinking about how to improve my lighting without going with some obviously illegal HID setup, and this looks like what I need.

I've also got some pictures of the snubber placement in this thread: https://www.rx7club.com/2nd-generation-specific-1986-1992-17/pinion-snubber-diff-mount-replacement-convertible-876959/. With no subframe/diff in the car, it should be cake.

I'm not sure what SirCygnus was talking about with the other intercooler bracket. The intercooler bolts directly onto the top of the UIM & the other side attaches to a separate bracket bolted onto the block. Maybe this other one was what was meant? The throttle and cruise cables both use the same bracket, and the right-hand spot is for the engine hoist bracket. So it's just two brackets you're missing.

Thanks for the information on the brackets and snubber link.

I briefly compared the new housings to the other side which had the silverstar in it still. The lighting off the hella was a very nice pure daylight white (almost HID looking) and seemed to outshine the silverstar (this is all with the light on in the garage), and I always thought the silverstars looked nice until now. I can't really say how well it lights up just yet as I haven't been on the roads, but I have used hella lighting before and I was never disappointed.

I know where you are coming from about the HID thing, I think these will be perfect. A good set of reflector housings with bulbs to match it will beat any cheap HID kit w/ reflector IMO.

More things got done today. Since we last left off, the subframe was ready to get dropped. But i'm going to side track here.

I wasn't happy at all with the CV boots I had got and installed before. They seemed flimsy and not thick like the O.E style boots and apparently they already started to tear near the clamp! I found out that I ended up getting universal CV Boots and that is most likely the reason why they were how they were.

I did some searching, I know mazdatrix carries the O.E. boots, but they want an arm and leg for one i say :fawk: to that! (No offense intended mazdatrix you guys have good service, I just think they are overpriced)

I found this website called RockAuto that carries parts for our cars. And I was able to find the exact O.E Style boots for these TII shafts. And they included the snap ring (the other kit didn't) and their price was very reasonable, less than the price of one boot mazdatrix wants! :bigthumb:

http://i1006.photobucket.com/albums/...9/DSC01101.jpg

If anyone is interested they are Raybestos #8161556 (Outer) & #8162930 (Inner). This is for S5 TII axles, i think S4 TII and N/A are different.

So I got the boots today, they were just want I expected. Heavy duty thick like the old cracked boots I took off originally. Here you can see the difference from the outer boots:

http://i1006.photobucket.com/albums/...9/DSC01091.jpg

And the inner boots:
http://i1006.photobucket.com/albums/...9/DSC01100.jpg

New outer boot going in:
http://i1006.photobucket.com/albums/...9/DSC01093.jpg

Very nice clamps:
http://i1006.photobucket.com/albums/...9/DSC01096.jpg

Finished products:
http://i1006.photobucket.com/albums/...9/DSC01106.jpg

And before we get to the subframe, I got the new front transmission seal from mazdatrix today. I was careful this time and used the old (technically new) seal I happened to damage last time, to the drive new seal in:

http://i1006.photobucket.com/albums/...9/DSC01136.jpg

New cover:
http://i1006.photobucket.com/albums/...9/DSC01138.jpg

Fork going installed:
http://i1006.photobucket.com/albums/...9/DSC01139.jpg

Now I have the CV boots, differential and transmission ready to go!