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Hi All, I'm new here. Currently I drive a 2006 Saab 9-2x Aero, which is a badge-engineered WRX. It has served me very well for years, but is getting on in miles and I'm starting to look around. I've got a crazy idea that I need some help with since I'm new to the Ford scene. I want to buy a 2014+ TC, short wheel base, with the 1.6L Ecoboost motor and swap the transmission to a manual. Ideally it'd be a 6 speed installed, but if 5 speed is much easier, I'd take it. I have done a lot of Googling and seen a couple of manual conversions on the first generation TCs, but nothing for 2014+. Have you guys ever seen it? Any idea on the viability? What I think I know (please correct me if I'm wrong): The 1.6L ecoboost is the same motor (detuned a bit) that is in the Fiesta ST A B6 manual transmission from a Focus would bolt up to the 1.6L ecoboost Since the TC is sold all over the world (except here...) with a manual, the frame work is mostly there (mounting points, firewall pass-throughs, etc.) so it shouldn't take a ton of fabrication I think the biggest risk/unknown is what I would have to do electronically. I'm hoping a Fiesta ST ECU would work since that has a manual and it's the same motor, but I don't know for sure. Traction control might also be an issue - maybe I would just not have it. My current biggest problem is finding someone who would be willing to do the work. I'm a relatively mechanically inclined guy and do all of my own maintenance/repair work excepting for body work type stuff. But a project like this without documented precedent seems like something I should have a professional working on. Also, I've never done anything as major as pulling/installing a transmission or motor, so I don't have things like an engine hoist or a lift or anything. I'm in the Denver, CO area and would love a recommendation for any mechanics/shops who might be willing to consider working on a project like this. I haven't bought a TC connect yet, and won't until I know it can be done for a reasonable-ish price ($5k?).
I found a source for the TC service manual and wiring diagrams on one of the Ford forums (maybe here?) https://www.factory-manuals.com/ I purchased the 2016 TC manual for about $70. It is a 7000+ page .pdf file. The manual appears to be a .pdf version of the Ford service software. The manual vendor gives you a printout of your TC configuration based on the VIN. The manual is very detailed and somewhat "bulky". The table of contents is too generic (section1, section 2 etc instead of names like lights, horn etc.) and appears to have lost the specific tags that may have been in the original application. The "hot links" in the manual don't work (e.g. section 43.5 will be in bold font and you should be able to click on it to jump to that section). There are thousands of pages of trouble shooting tables. It takes a while to browse each section to the overall layout. The manual explains how each component works and also explains some of the programming in the ECU. For example, did you know there is an aux electrical heater for the cabin heat that turns on when the ambient temperature is less than 48 deg F and the heater turned to max? The location of every plastic tab on the panels are shown in 3-D color diagrams. Overall I am very satisfied with the manual. The wiring diagrams are in color and are exactly what I was looking for. The section on the configuration of each electrical connector is missing but the wiring diagram identifies the pin number for each wire on a connector. You can make unlimited copies of the .pdf file. Something "bad" is supposed to happen if you share the file. The site appears to be legit and I think it was $70 well spent.