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dotmaster206

2014+ TC Manual Conversion

66 posts in this topic

Been a while since I last updated.

A few items:

The clutch pedal from the ST has been swapped over to the TC. It fit perfectly. The cutout for the clutch lines was already in the TC, as were the bolt holes to mount the pedal. All hail Ford's manufacturing efficiency and platform sharing!

TC%20with%20clutch%20pedal1_zpsxv497rmt.

They also pulled the center consoles out of both vehicles to see how the shifter mounting can work. One option is putting the ST center console into the TC and having the shifter sit on the floor. 

They mocked that option up:

ST%20consol%20inside%20TC3_zpsdk7iumv8.jST%20consol%20inside%20TC3_zpsdk7iumv8.j

The console doesn't line up perfectly, as you'd expect, so there'd be some fabrication to pretty that up. But the shifter itself does mount there and the e-brake works there as well. 

Vaccar is going to make some calls to the UK this week to find out what we'd need to order to get the shifter to mount and work from the original shifter location without swapping center consoles. Depending on the cost/availability of those parts, it is my preference to go that route instead of mounting it to the floor. I like the idea of keeping the van-ness intact in that sense, and it will look more OEM that way as well.

Here's a picture of a UK van with a 6 speed shifter. 

UK%20EXAMPLE%20MANUAL%20TC_zps8dqg3uj0.p

 

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Nice. If you can get the OEM Part you should have them put the console in the  box also.  The direct fit will pay for itself!

What are you doing with the Old Power plant?

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On 5/4/2017 at 9:05 AM, dotmaster206 said:

I have to give you a little credit, actually. Your posts about buying a TC a while back probably added to the bug in my head about them. 

It's definitely a great car, it's a bummer that the turbo, manual model is not available here in the states.

Perhaps Ford will see that there is a market for it here... although, I'd love a 4x4, manual transmission, turbo-diesel too... long wheel base tho - I need the extra room :)

Seriously tho, I'm so blown away by your drive and progress. Can't wait till you can take it for a test drive. 

 

 

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On 5/8/2017 at 6:22 AM, G B L said:

Nice. If you can get the OEM Part you should have them put the console in the  box also.  The direct fit will pay for itself!

What are you doing with the Old Power plant?

I agree, it may end up being cheaper and better - win win! 

The old 2.5L duratec and transmission will get sold; either to a salvage yard or an individual. Vaccar actually threw out the idea of putting it into the FoST shell a while back, but I am doubtful it'd be a higher net value to me to sell it that way. 

 

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A question for any Europeans on this board, if there are any active members: how do you get Ford parts generally? Do you have to talk to an individual dealership or is there an official/reputable online dealer that I might  be able to use?

I've been able to easily find shifter cables (they call them gear selector cables I guess) for the last generation of TC, but not the 2014+. Any idea where I should look for that? 

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10 hours ago, dotmaster206 said:

A question for any Europeans on this board, if there are any active members: how do you get Ford parts generally? Do you have to talk to an individual dealership or is there an official/reputable online dealer that I might  be able to use?

I've been able to easily find shifter cables (they call them gear selector cables I guess) for the last generation of TC, but not the 2014+. Any idea where I should look for that? 

There are not many B-category parts available for the new shape yet.

I would contact Paul Leepu Hayes in facebook who does a lot of body mods for Connects, he can probably lead you to mechanical parts as well.,

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Keep me posted on the Drive train

Can't wait for more pictures!

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On 5/15/2017 at 1:27 AM, dotmaster206 said:

A question for any Europeans on this board, if there are any active members: how do you get Ford parts generally? Do you have to talk to an individual dealership or is there an official/reputable online dealer that I might  be able to use?

I've been able to easily find shifter cables (they call them gear selector cables I guess) for the last generation of TC, but not the 2014+. Any idea where I should look for that? 

I'm an American in Germany for 9 months. I drive at diesel 6-speed.

I haven't really looked for online sellers, but if you're desperate, PM me and maybe I can help you out at my dealer. His English isn't awesome, but we can usually figure things out.

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Another update and another question: I did get in touch with Paul Leepu Hayes as suggested by @mrtn. He offered to get me some part numbers as he has access to the Ford parts catalogue which was great. 

On my own googling around I sent an inquiry to FordpartsUK.com and they got back to me yesterday - very helpful. They got me pictures from the catalogue and are willing to ship to the US for me, so I will probably be ordering from them. 

My question to the Euro folks out there: have you ever seen/heard of someone swapping the shift knob from a Focus ST into the Transit Connect 6spd? I ask because I can order one of two versions of the shifter assembly; a cheaper one with a plastic shift knob and a more expensive one with a leather shift knob. If I can swap the Focus ST one on easily, I'll just get the cheap plastic version. If I'm not sure that is possible, I'll get the leather one so it looks/feels better. 

A thanks as well to @J_Westy for the offer to work with his local dealer in Germany on my behalf. 

 

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On two previous cars I've had, the OEM shift linkage was so imprecise that my very first mod was to buy a shifter kit and that improved driveability 200%.  If it appears you're going to have to buy the OEM shift linkage, you might want to consider getting something better and it might even be cheaper than buying the factory parts  -  The last kit I bought (for a Mazda) was less than $75

Since we don't have any TC's this side of the pond with manual transmissions, maybe a few of our European owners who have manuals in their TC's could tell you what the factory linkage is like  -  Is it great, or do you wish there was something better?  Is there a shifter kit available for a manual trans TC?  What do they cost?

Don

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That's a good point. I haven't been able to find anything in shifter upgrades/aftermarket stuff for the manual TC yet. Nor have I seen any complaints, though. It is a very simple cable system, so if it can be upgraded later I'll have no problem doing it I'm sure. 

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17 hours ago, Beta Don said:

Since we don't have any TC's this side of the pond with manual transmissions, maybe a few of our European owners who have manuals in their TC's could tell you what the factory linkage is like  -  Is it great, or...

Well, I came out of a Fiesta ST 6-speed in the US into the 1.5 diesel 6-speed Grand Tourneo Connect.

I would say it's quite good and worth starting with, but for sure I'm not speed-shifting it ;-)

For whatever reason it's way better than some of the Ford rental cars I've had over here - Focus, B-max, etc... those might have been 5 speeds though, I can't remember exactly.

I'm enjoying this build though! Keep up the posts!

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Is the shift assembly a cable set up as on most Transverse engine installs?  If so the Aftermarket shift is less available.

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Yeah it's a cable shift, same as the Focus ST. 

Vaccar has ordered the OEM shifter that I found from Ford Parts UK. I wasn't able to find proof that anyone swapped an ST gear knob onto a TC shifter, so I bought the whole assembly with the leather knob just in case the ST one won't go on there. Cost an extra $50, so not a huge deal. I expect that to take 2-3 weeks total to get to Vaccar. In the mean time, they're going to start on the engine installation and then move to the wiring harness. 

Last week they installed the brake and gas pedals from the FoST, they fit perfectly, just like the clutch did. 

2017051695183634_zpsaw31kgat.jpg

 

The LSD was at a transmission shop last week and got installed, and they took the opportunity to take a look at the clutch to make sure it was in good shape. It is a Spec Stage 3+ clutch, which is pretty aggressive and a lot more race oriented than I would have chosen myself. Vaccar test drove the ST before pulling the motor and transmission though and didn't think the clutch was annoying or difficult like you'd expect from such an aggressive setup. So, I'm going to leave it like that for now and see if I get used to it. If not, I'll swap in a more OEM type organic clutch and sell the Spec one. Based on what they said it felt like driving the FoST though, I think it will be fine. They didn't experience any chatter or anything. Spec also looked at pictures of the clutch and said it was very new looking - just broken in. So lots of life left there. 

20170516_131037_resized_zpsluuyx5gc.jpg

 

G B L and mrtn like this

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Great call on the shift, If that is not right the whole job will suffer.   Looks like the pressure plate and the flywheel  and the pressure plate will get buffed up. The extra cost when put against the whole project is very small. 

This project is not  a necessity . If it comes out correctly the cost will be worth it. 

Good show keep us in the loop

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Got a sweet update today - the ST motor is in the van.

 TC-ST%20install4_zps2h2nbtfn.jpg

 

It bolted right up with no complications. The clutch lines are hooked up as well, but that's all for now. Big milestone!

mrtn and G B L like this

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