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Topic: Manual Cossie Conversion (Read 1397 times) |
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mazzy_j
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Posts: 664
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Manual Cossie Conversion
« on: Jun 14th, 2006, 8:27am » |
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Hi all,
i'm finally getting round to converting my cossie to a 'waggly stick' only i need a bit of advice about some parts of the conversion.
I've had a fair bit of help from a couple of people on here already  and a few initial problems i can see ahead are as below...
1) What would be the best way to operate the clutch?
I've initially decided on using a cable operated clutch, but i've managed to source a good diesel gearbox and propshaft a mile from where i live and its just been pointed out to me that there is no hole in the gearbox for the clutch lever arm to go through! Could i make the hole for it?
2) What pedal box should i use?
If i went down the cable clutch route i wouldn't be able to use the pedal box from a diesel scorpio because its hydraulic, would one from a sierra do?
3) The spigot bearing?
I would need to use a 12v one?
Thanks for any help,
Matt
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howiedintheplace
Senior Member
Based near Evesham
Posts: 1194
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Re: Manual Cossie Conversion
« Reply #1 on: Jun 14th, 2006, 5:40pm » |
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Matt when you fit the 2.9 front to the diesel box it is as a cable operated clutch as you have just replaced the whole front end.
You now have 2 choices.
You can convert the box back to hydralic clutch & use a Scorpio set-up
or you can stay with cable & fit a sierra clutch pedal?
Yes a 2.9 xr4x4 (88 - 93) spigot bearing
Just so you know what your building look on ebay for item 4644095860
That was the last box I built, you can see they are worth a fair few quid as they are so rare.
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Dave
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Baz
Moderator
Senior Member
S Reg. 1998 24v Cosworth S2.9 COS (Deceased)
Posts: 4009
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Re: Manual Cossie Conversion
« Reply #2 on: Jun 14th, 2006, 7:16pm » |
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I know this is the Baz negative side again, but is it really worth doing to a 10 year old or so car? The blooming rust will have it before long!!
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Highlander
Moderator
Expert
13 Scorpios, XR4x4, Suzuki SJ413 for off road :)
Posts: 8244
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Re: Manual Cossie Conversion
« Reply #3 on: Jun 14th, 2006, 11:06pm » |
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Victor Meldrew doesn't have a look in.... 
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on Oct 17th, 2011, 12:35pm, Simmo wrote:I give up !  Too much for an old boy!  |
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Baz
Moderator
Senior Member
S Reg. 1998 24v Cosworth S2.9 COS (Deceased)
Posts: 4009
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Re: Manual Cossie Conversion
« Reply #4 on: Jun 15th, 2006, 12:08am » |
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I DON'T BELIEVE IT!!
I know....but it just seems all a bit.......un-necessary!!
I know I've strapped TV's and sat nav and LPG nad other things into and onto mine but that enhances the car (IMHO) and makes it more pleasurable to drive but changing the gearbox and all the work that must go into it (although a very comendable achievement) just doesn't cut it for me because I fail to see the actual benefits. I used to drive a 2.9 4x4 Granada Scorpio which was a manual and I longed for a 4x4 automatic!
Still.....it will be interesting to see if the guy who has already done the conversion comes to Harewood!
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LiverpaulH
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My bird!
Posts: 423
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Re: Manual Cossie Conversion
« Reply #5 on: Jun 15th, 2006, 7:35am » |
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I quite like the manual box idea, and I wis you tyhe best of luck matt. I know that darkdestroyers conversion is superb and that cossie doesn't half fly with the waggly stick, very impressive car.
Advantages....quicker and (boring hat on) better fuel consumption and stronger gearbox imo.
Disadvantages....cost and time to convert and more effort to drive!!
Keep us informed of your progress.
Paul 
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Still hankering after a new scorpio- Aus BA Falcon, 5 years later and I still love it!
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mazzy_j
Full Member
Posts: 664
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Re: Manual Cossie Conversion
« Reply #6 on: Jun 15th, 2006, 8:32am » |
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Quote:| The blooming rust will have it before long!! |
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The good thing about the cossie i have is it doesn't have any rust on it at all at the moment  Its only used as a fun car so the tin worm will be kept at bay
I know it'll take time and money, but hey, it'll keep me out of trouble... Plus getting rid of that horrible auto box (IMO) it'll mean more of the engines horses actually get to the wheels and making it more pleasurable and involving to drive
To date, the progress and parts i have managed to source so far are:
1) A low mileage diesel gearbox and propshaft (pick up on monday)
2) A 12v flywheel and release arm (money sent off, just waiting for delivery)
3) Will get down to Mr Fords to pick up a new spigot bearing.
4) Been looking at clutches on ebay to get an idea of what would fit, Would i be right in saying that so long as the clutch is for a rwd mt75 cosworth (escort of sierra) it'll fit?
5) I'm going for the cable clutch set up, but was wondering would it be possible to simply bolt a clutch pedal from a sierra to the existing pedal box (will need to cut down the brake pedal of course) or is the assembly from the sierra a one peice affair which will need to be modified?
Will be good to see the one at Harewood and how its been done, I'll keep you all posted as to how its coming along.
Matt
p.s. Dave, i realised last night that becuase i'll be changing the front part of the gearbox it wont matter about needing to make a hole because it'll already have one! Doh! Not to worry
Edit: I think i've just found you on interford.co.uk  A 3.7L BOB Cosworth XR4x4 project. Got a lot of very useful stuff on that site, especially on converting sierras to 24v manual's.
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Dave2302
Senior Member
2006 Mercedes S55 AMG, Retired Barefoot Waterskier
Posts: 1119
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Re: Manual Cossie Conversion
« Reply #7 on: Jun 15th, 2006, 1:32pm » |
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Hi, just to add a bit of fuel and a different interest LOL !!!! I am a retired Auto Box specialist and a hot rodder / petrol head who has been carrying out conversions for some 25 plus years. I have also neatly and succesfully done the following to my 97 model V8 Pontiac Firebird. If I wanted to turn my cossie into a manual, I would retain the 4R44E auto box, fit a "Tiptronic" type of shifter assembly together with an electronic switching interface between auto trans and shifter assy. The 4R44E has the capacity to give 5 separate ratios plus with the converter lock one effectively has a 6 speed sequential shift transmission system. I haven't looked at this in detail for the Cossie Scorp cos I love mine as auto, but it is possible that the existing PCM could be re programmed to accept the switching function, and maybe retain an automatic mode too, as we did with the Pontiac. Of course to re - program you need the correct software, and not all PCMs are re flashable but I beleive the Cossie one is?? (My mate has access to programming software as he programs for several major car manufacturers around the world). Bearing in mind the hi tech nature of the 24v Cossie I reckon this would be a d**n good project.
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Dave "The 'ol Bear" ex Footer !
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sector-9
Senior Member
No scorpio anymore
Posts: 1069
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Re: Manual Cossie Conversion
« Reply #8 on: Jun 15th, 2006, 6:21pm » |
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Ahhh but you still lose horses driving the hydraulic pump, in the torque converter (except on lock-up) and the fact it's only a four-speed 'box so the ratios are more of a compromise than on a five-speed. Not to mention the impossibility of push-starting the car and the usual routine maintenance needed regardless of what controls gear selection.
I admit though, I'd rather have an automatic than a manual - has anybody added an A4LD to the diesel...?
Darren
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Baz
Moderator
Senior Member
S Reg. 1998 24v Cosworth S2.9 COS (Deceased)
Posts: 4009
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Re: Manual Cossie Conversion
« Reply #9 on: Jun 15th, 2006, 7:18pm » |
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Darren,
there was an automatic diesel available in the facelift model. Quite a rear beasty though
Baz
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howiedintheplace
Senior Member
Based near Evesham
Posts: 1194
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Re: Manual Cossie Conversion
« Reply #10 on: Jun 15th, 2006, 9:39pm » |
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Well I do think a auto is under rated in this country.
A auto if set up right will let you accerate faster than a manual & are now so good that it don't make much sense having a manual car unless you you really do want to be in control of the gearbox.
Having said that it would be costly to uprate the auto box so the manual has the edge pound for pound I guess.
Dave 2302- well interested in any info you have about doing what you say to a 24V
Been looking at a similar kind of thing myself Any more info?
Matt
I think the best thing would be to get a Granny pedal asembley.
The diesel Granada had a cable clutch.
You will have to figure that one out as I have never had to do it
& yeah I had a 3.7L BOB that I sold & is now fitted to a Cortina with a super charger bolted on to it
When you fit the spigot bearing be sure to clean the hole in the crank first as it will have surface rust on it.
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Dave
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LiverpaulH
Full Member
My bird!
Posts: 423
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Re: Manual Cossie Conversion
« Reply #11 on: Jun 15th, 2006, 9:41pm » |
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on Jun 15th, 2006, 7:18pm, Baz wrote:Darren,
there was an automatic diesel available in the facelift model. Quite a rear beasty though
Baz |
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Rare, but not that rare on ultima diesels.
I test drove a couple with autos before buying my second manual, but thought the box doesn't really suit the diesel, kickdown didn't work on either and they seemed pretty sluggish. It may have just been bad luck with both turbos dumping too early though.
Paul
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Still hankering after a new scorpio- Aus BA Falcon, 5 years later and I still love it!
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sector-9
Senior Member
No scorpio anymore
Posts: 1069
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Re: Manual Cossie Conversion
« Reply #12 on: Jun 16th, 2006, 8:39pm » |
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Maybe I need a sluggish car to stop me getting SP30s! I do like the smoothness of autos but find that until the turbo gets up to speed the diesel engine is a bit of a sluggard anyway. As maximum torque is developed at just over 2200rpm it makes me wonder why they've put such a large turbo on - surely a smaller one would spin up quicker (at expense of strangling top-end revs which we don't need anyhow)? Of course, the new VGTs would be better still but the original ECU isn't smart enough to work one.
Darren
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Matt
Senior Member
Manual'd and a 4.0 in the making
Posts: 2816
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Re: Manual Cossie Conversion
« Reply #13 on: Jun 18th, 2006, 12:44pm » |
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hi all
Quote: Darren,
there was an automatic diesel available in the facelift model. Quite a rear beasty though
Baz
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there was a red one on ebay a week or so ago, didnt sell for very much either
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FDS2000 Scans - Birmingham
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hellblue
Full Member
Ill have silver,it dries just as fast !
Posts: 210
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Re: Manual Cossie Conversion
« Reply #14 on: Jun 20th, 2006, 10:59pm » |
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Try these sites ford power uk & caprisport . im collecting parts for my cortina at the moment BOA engin, BOB cams, hybrid 2wd/4wd mt75, 2.8 capri flywheel (lighter than 2.9 ) cossy clutch with hydraulic release bearing mod (so you could use hyd. clutch pedal, no melted cable on exhaust & lighter pedal) try AWC 01923 225918 to buy your clutch parts as they sell each item & not kits. dont forget to leave the range sellector in park when removed or eecv will throw one looking for auto box, & drive it like you stole it ! check your input shaft length, see caprisport gary
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Gary
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mazzy_j
Full Member
Posts: 664
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Re: Manual Cossie Conversion
« Reply #15 on: Jun 21st, 2006, 9:26am » |
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Cheers Gary, things have stalled at the mo cos the person who i was meant to be getting a diesel gearbox and propshaft off last monday (Steve Savill, yes the ebay seller) hasn't taken it out of the car yet 
Another good site i've found is interford.co.uk, lots of good stuff on there too
Matt
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