alright - here goes. KL-P5-take2

[ihone]

The K8 flywheel is no longer carried in the parts stores, so I was told by the part stores.

Found one on ptalk - he's expressing it to me today and I should have it by Wednesday for a light sanding (it's got a few scars in the material) and installation.

 

[ihone]

anyone got that bracket that goes on the manual trans for a '02 p5? Not the mount itself - just the bracket.

I'll make something if I can't find one, but I'll buy it if the price is right!

 

[ihone]

ok, and since USPS is such a bunch of asshats - I'm still in need of a KL flywheel. I got one from a member of PT, he shipped it (I got confirmation and all), and it made it to USPS warehouse in PA - and they lost it......wtf.....

Anyone got a KL flywheel that isn't in too bad shape that wants to sell it? Reasonable pricing only please.....I paid 20 bucks + shipping for the last one.....lol.

 

[Teeson]

I may. I have a lightened one in a box, I'll see if I have time to pull the trans and check the stock one today or tomorrow

 

[ihone]

Thanks - got one on the way yesterday from PT. All I had to pay was shipping.

 

[Teeson]

sweet!

 

[ihone]

whew.......gettin those butterflies again. I got this feeling just before finishing rd. 1 of the ATX/KL build. Then I drove it....then I drove it more.....but only had 2nd gear. 1st to 2nd - that lil bastard is FUN! I can only imagine how much more fun it's gonna be with the MTX.

 

[Lewis7789]

I took the stereo out of my KL P5 it sounded so good. And I'm a snobby musician. Haha! You'll love it. Glad it's coming along, mate!

 

[ihone]

The stereo is one thing we (yeah....my wife and kiddos....and me...) are looking forward to again. the Saab doesn't have a working noise-maker - so my singing career has taken back off like you wouldn't belive.

I could go platinum with some of the tunes I come up with.....

Serious question: the top mount bracket on the trans. I still don't have one...and if I have to - I will make one. I'd much rather just buy one, but I'd have to source that bracket - and jimellis wanted WAY too much for it.....every MSP around here doesn't have the engine or trans any more.....kinda leaning toward making a solid steel bracket and making it work...lol.

 

[Lewis7789]

Did you find out which one it is? Did you still need a pic? I can snap one tomorrow morning. I remembered the other day when i was in the garage "Damn it, I never took the pic of the mount for ihone."

 

[ihone]

it's the actual bracket that bolts to the top of the Transmission itself. Not the mount that bolts to the framerail - but the piece that goes on teh tranmission that snugly fits that insulator on the mount.

 

[ihone]

Flywheel hit League City, TX this morning at 3:50AM - through sorting by 10 - out for delivery for this afternoon.

.......come on 4'oclock! I gotz work to do!

 

[Teeson]

is it the one from a KL engine or a protege? I can snap a pic if its the KL one, as I have one on a stand

 

[ihone]

Teeson - it's the one from the Protege.

update:

Trans is in! flywheel showed yesterday about 3PM, so it was instantly to the batcave to work on her. Trans is mounted (with exception of the mount that goes to the driver-side framerail - going to have to figure something out for that one), linkage is connected (gear selector bar is kind of loose and this produces a little slop in the shifter - is there a bushing that goes in there?) and everything was coming together nicely - then at about 10:30 - I started getting sleepy.

Need to find 2 bolts for the slave cylinder (lunchtime run!!) and see if there's a bushing in that shifter "dealie" on the back of the transmission where the shifter linkage connects (looks like a rod with a "U" on it to reach around the assembly).

Other than that - I should finish today if all goes well.

 

[Lewis7789]

When I swapped out my P5 shift linkage for a PGT linkage my shifter was really sloppy too. Someone makes replacement teflon bushings on PT.com but honestly, they are stupid expensive. I ordered both sets of bushings for $50.

 

[ihone]

I'm looking at just possibly drilling out the linkage fitting and putting a larger diameter bolt in there. Makes it solid, and leaves no room for slop as long as it's tight.

 

[ihone]

update:

MTX swap has been completed - but now I Have no spark when trying to start it. I'm attempting to troubleshoot the problem - but something just seems strange.

- the CE light just stays on - even with TEN and GND jumpered together. It doesn't flash, doesn't change at all.....just stays illuminated.
- The grounds; I checked, rechecked, and even rechecked and cleaned them all with contact cleaner to ensure a good connection. They all ohm out to 0.
- Crank position sensor ohms at 1.5k......service manual states 520-580 ohms. No crank trigger = no spark? How'd this fail, is my question.

 

[ihone]

ok - got her back up and running tonight! My son pointed out one harness connection I disconnected when I was freaking out looking for a short.

So - KL swap = done.
KL ATX > MTX swap = done.

Now to get the intermediate shaft tied down, the body all back together, and the vent system won't switch modes for some reason.....is it vacuum controlled? Where's the vacuum feed line to make it work then? Because I need to switch on the defroster like...NOW! lol...

 

[Teeson]

lol I love the stupid mistakes... does the Protege ECU control any part of the system? I know that the system is well linked together. I deleted my A/C and missed a plug, half the system shut off. The panel around the radio/climate controls isn't too difficult to remove...

 

[ihone]

Didn't mess with any of the climate controls though...which leads me to believe it's a vacuum line I missed somewhere.

Hell......I didn't even tie any vacuum back into the system from the new engine, except the master cylinder booster.