I present to you, the Passion5

[FORZWIN]

I hear you guys...I'm working on some pictures. For 2 weekends in a row I've tried to put the motor in but something always comes up, today it was a complication with the half-shaft and knowing how much easier it is to work on it without the confines of the engine bay I called off putting it in.

Since the last update, I finished the mazda6 brake upgrade, sans ebrake. I bled the system and it felt as if the system was very soft on the first push, but every push thereafter would feel great. I ordered a new master cylinder, but it has yet to arrive, hopefully that resolved the soft pedal and to be honest, the rest of the system is new, why not do the master cylinder? Today, it seemed to be an off day. I got the clutch/flywheel/trans bolted together, but when I went to put the halfshaft in, I had a hard time getting the flange to bolt up. It seemed as if the offset was all wrong, like the flange was too thick, however I do know that it bolts up as I tried it prior to the install. I'm having a machine shop take a couple of mm off of the shaft to see if I can't get it to line up.

Things just weren't going well today, I snapped some pics, but over all it was just hurdle after hurdle. I should probably take some time to clean the space, spent too much time looking for parts. As soon as I get the halfshaft back (if it fits) we'll be putting the motor in , then it's a few weekends getting the engine bay together and doing all of the wiring.

 

[vampyrate]

Are you runnin oem lines of ss? Maybe some ss lines would also help with the pedal feel.

 

[aMaff]

no, if the pedal is that soft, no amount of SS lines will fix it. Something else is the problem, and I think he's on the right track w/ the M/C, so long as the slaves (the caliper pistons) aren't leaking). If pressure comes up with subsequent pedal presses, there's definitely a leak somewhere.

 

[FORZWIN]

Yea, I'm already running the stainless braided lines, but as aMaff pointed out, if it builds (and holds) pressure on the second pump there is a void in the system somewhere. The way I see it is that the car sat for 1yr+ without and fluid in the system and all of the lines were left open; it's realistic to think that there is air still trapped in the system and that the master cylinder could be toast. The calipers have 20k miles on them, I doubt they are to blame and the rest of the system is pretty new, why not replace the MC. I have a power bleeder that I'm going to use once the new MC comes in.

I also entertained the idea that the new calipers are sucking more fluid than the original protege calipers, thinking that massiv calipers would take more fluid, but it turns out that the MZ6 MC is actually smaller than the P5 unit. That means that it should take less force to achieve the same amount of pressure, though the difference was negligible. Hopefully 'll get some pics up tonight.

 

[MasonMetcalfe]

I was Bored.

Use as you like, if at all.

 

[FORZWIN]

That's DOPE! Haha, it made it as my new phone background for now.


Thanks!

 

[MasonMetcalfe]

:d

 

[FORZWIN]

So here's an update (with pictarz!!!)

Custom brushed evil-M

Refinished Flywheel:

$32 worth of flywheel bolts...sigh...

I don't need no stinkin' protege studs! FS protege's are tough to find around here, and given I didn't get the FS with my P5 i got crafty. The pitch is M12x1.25 so I found a die and got to it. I did both studs then measured the studs on my dad's MSP to get the proper length.

Next is my current hurdle, I picked up the correct 626/mx-6 bracket that everyone references and it fit before I put on the transmission, but now that the trans is in place, I can't rotate the bracket into place to line up with the holes. When I got the motor it had the two bolt flange, but the mx-6 folks were pretty certain that 3 bolt flange is what is required for the ZE. I'm thinking about pulling a 2 bolt flange off of a later model KL to see if that works, if not, than I may be cutting it up and welding it to fit. Not sure what you other guys are doing for half-shafts, I know Justin customized his own halfshaft. I did take it to the machine shop to take off about 2mm of the flange but that wasn't nearly enough.

 

[Joost27]

Wow that is messed up. I was always told the 3 bolt flange would work perfect with the ZE. the two bolt will not line up with anything once in the transmission. It really makes me wonder what shaft the ZE is ment to use.

 

[FORZWIN]

Hence my confusion. This is what everyone says they use, but I wonder if something with the blocks changed when they changed the shafts. Hence, I'm thinking about grabbing a 2bolt KLDE flange from a later 626. Worst cash I'll be fabricating like you did, what did you start with, your FS halfshaft?

 

[Joost27]

I had the FP before the v6 so it had an f-series trans which the shaft wouldnt work with the v6 gseries. So i bought a two bolt later model mx6/626 shaft. None of the the bolt holes ont he 2 bolt lined up with any of the holes on the block. So We cut the 2 bolt flange off and made one with three holes that lined up with the block

 

[bullshark524]

what i did with mine was much easier then what justin did. the half shaft i bought had 2 holes but also had a spot that looked like it was meant to have a third hole but it just didnt get drilled out. i drilled out the third hole and then elongated another hole that was off by a hair. and that was it. unfortunatley i dont have any pics but i can get most likely get some tommorow but if i cant then i will get them mon cuz i have off of school and work then. and i will try to find out what halfshaft i bought

 

[FORZWIN]

See that's where my confusion lies, everyone always says that the problem is that the holes don't line up, but I can't find a single post that talks about the issue I'm having. I think next weekend I'll get by the junkyard and pull a halfshaft from a newer (96+) 626 and see what shakes. perhaps something changed with the blocks on the curve neck ZE's? The halfshaft I picked up was out of a 93 probe, which shouldn't make a difference as it looks identical to every other one I've seen.

I think I can follow what you did by your description, but any pictures would be great. I could always remove more material from the flange, but I don't want to risk the strength of the part.

 

[CheeseHelmet]

This is perhaps a stupid question, but why can't you simply ask Mazda about your predicament? There must be someone at Mazda HQ you could call about things like this...

 

[FORZWIN]

Not a stupid question, but in my experience, when you start asking questions about motors that were never made here they get into a "can neither confirm nor deny" mindset. I could ask if there were any changes to the halfshaft in 1996, which could support my current theory, but there are a couple more caveats. No one around here will support you without a VIN, if I give them my P5 VIN and start asking questions related to the KL they are going to label me an idiot or offer no support as they don't want to be responsible for my misfortune. In addition to that I don't know when the block was manufactured so I can't give a specific manufacture date. Thirdly, I can't get off of work to go pick the brains of the mazda folks and very few parts dept's are open on the weekends around here, support over the phone is out of the question. Though I could browse the online parts catalog I suppose.

I've got a buddy that's a nissan parts guy, maybe he knows an outstanding mazda parts guy that I can talk to. I've tried doing that sort of thing with my other swaps but the majority of the parts guys I run into are helpless without a VIN and can't really think outside the box or are not willing to.

 

[CheeseHelmet]

That's kinda sad, you'd think they'd be enthusiastic to help you with your project. I suspect the guys at the dealer I go to would lend a hand...

Naive question #2: Doesn't the motor have a VIN stamped on it somewhere that you could give them?

 

[Lewis7789]

I havent mated my tranny to the motor yet but I've test fitted the intermediate shaft and mine seems to line up okay. But then again, I don't have the same motor as you guys. JDM MX-6 tranny with a JDM Xedos8 motor.

 

[bullshark524]

okay so i just uploaded the pics. however i cant find the reciept but i will continue looking cuz i have a few boxes around my house full of reciepts.
also doing this reminded me i still need to elongate one of the holes
the hole on the right needs to be elongated to the left. the hole on the top is not gonna be used and the hole on the left is the one i drilled out. the metal where i drilled was a different shade

 

[FORZWIN]

That's kinda sad, you'd think they'd be enthusiastic to help you with your project. I suspect the guys at the dealer I go to would lend a hand...

Naive question #2: Doesn't the motor have a VIN stamped on it somewhere that you could give them?

Yea, I was a bit younger when I did my first few swaps, maybe that had something to do with it. In reality though, by the time I do most of my research I'm more knowledgeable than they are on the specifics of my swap. Not sure if I would have better luck now or not.

I havent mated my tranny to the motor yet but I've test fitted the intermediate shaft and mine seems to line up okay. But then again, I don't have the same motor as you guys. JDM MX-6 tranny with a JDM Xedos8 motor.

You just had to go and be special That was my deal, when I tested the half-shaft it lined up great and looked like it was going to work, but that was while the motor was on the stand and without the trans.

okay so i just uploaded the pics. however i cant find the reciept but i will continue looking cuz i have a few boxes around my house full of reciepts.
also doing this reminded me i still need to elongate one of the holes
the hole on the right needs to be elongated to the left. the hole on the top is not gonna be used and the hole on the left is the one i drilled out. the metal where i drilled was a different shade

Thanks for the pics, that's my other alternative at this point if I can't find a working shaft.

It cost me $50 to have the machine shop take ~2mm off so I'm not sure if I want to keep paying them so that I can take a little off at a time, then my concern is the strength of the bracket after all is said and done. I'll research a little more tonight and see what shakes.

 

[bullshark524]

why dont you ask the machine shop to do an angle cut like this. i feel it would do more to make it fit then just traking material off the face