I present to you, the Passion5

[FORZWIN]

I'm a bit purplexed with the linkage as well. I'm running the stock P5 mounts filled with window weld, but the engine bracketry is all KL. Brian has a spare front bracket from a spare FS trans, I'll give that whirl and it should allow that front mount to sit snug. Should I be running FS engine bracketry front and rear? I wonder if I should move to the PGT rear tranny bracket and see if that helps my front crossmember clearence, right now its looking like I may have to notch it if I can't get the motor to sit up any higher.

I'll run by my cousin's house and pick apart the probe a little more tonight for some misc items that I left and maybe tomorrow I'll run out to my parents and throw some wrench time at the P5. I'll measure the shift linkage assemblies from the PGT and P5 to see if there is a difference. It could be that the overall length of the KL is shorter than the FS and thus it's moved the assembly towards the driver, perhaps the KL assembly can account for that. Maybe the KL is positioned further back than the FS was and that's why the tension rod is 1/2" too long? we got the selector arm to bolt up just fine and we ran through the gears without issue.

I'm hoping there is enough side-to-side slack in the mounts to get that power steering pulley off of the subframe, it's not tight, I can spin it with a little resistance, but obviously I can't let it run like that. There isn't any play in the front/rear mounts so I think I'm stuck with the way they sit, maybe putting in the front mount will help get the trans off of the crossmember.

Otherwise I'm pleased with the way everything fits and it looks as if it will be fairly easy to maintain and work on down the road. I'll try to get better pictures of the issues at hand after I get over there Wednesday.


Thanks for all the help 'gents.

 

[Lewis7789]

Well, maybe Justin can add some knowledge here, but I'm pretty sure I had to switch all my FS-DE engine mounts to the KL and use the P5 chassis mounts. I'm not sure if it's absolutely necessary but that's what I did and everything bolted up okay. Like I said in the PM, the KL mounts were about 1" wider than the P5 mounts. That may be throwing everything off.

And I quickly measured a KL'ed 626 shift linkage at the junkyard and I think they were the same as the P5. But it was a quick measurement. If you can get a good measurement of them I would greatly appreciate it.

 

[FORZWIN]

Sure, I'll get you something tomorrow night, I won't have the P5 linkage to reference until then. Thanks.

 

[FORZWIN]

While it may not sound like much, we made some solid progress tonight, learned a few new things along the way. I've got some pictures below that show the issues I ran into.

Fit and Finish
In short, the motor fits great now! We loosened up all of the mounts, removed the MX3 rear mount bracket and installed the P5 front mount bracket which pulled the engine off of the front crossmember AND the PS pully of of the subframe!. The two side mounts looked fine, but the rear mount appeared to be causing an issue. I originally used the MX3 transmission mount brackets since I didn't get a tranny with my P5, but they look to position the motor too low. Brian has a rear mount bracket and will be donating that as well, but at this time, everything is lovely.

Shift Linkage
Evan, before I think I was a little confused as to what you were referring to when you were talking about your shifter being misaligned since the swap. After hooking the P5 assembly to the MX3 tranny, OH MY DAMN! Shifting to 2nd and 4th had my wrist banging on the ebrake lever and 1st/3rd/5th looked like the car was in neutral. Since I had the PGT linkage handy I decided to take a measure and it turns out that the PGT shifter arm is almost an inch longer and if used in place of the P5 shifter arm, it takes the throw back to normal. Sadly I thought about shooting video after we had already made the swap. But if you're driving around with the stock linkage, I feel your pain. My linkage is now made up of the P5 torque rod and PGT shifter rod; the parts were sourced from a '96 Ford Probe GT and while I speculate that any KL shifter rod would work I can't be sure. The P5 torque arm appeared to be 1/2" too long, but after putting a little muscle into it I was able to get it to line up, it wasn't bad tough, but at first glance it does appear to be1/2" too long; just give a solid push on the rod toward the rear of the car and it will line up. Another interesting find was that the bolts/bushings were different between the shifters where the rod connects. We were able to replace the P5 plastic bushings/bolt with the PGT's metal sleeve/bolt and omit the plastic bushings. Another neat find was that the plastic bushings used in the P5's stock shifter could be reused to replace the decrepit bushings where the shifter rod meets the selector rod of the transmission. Let me know if none of that makes sense, I tried to take pictures of what we were doing and showing the differences. I took a video of the final result, but I didn't have one for what one could expect when using the full P5 linkage, perhaps Evan or Justin have a video?

I'm also not too sure about the 626 fans, they are a tight fit with the headers and o2 sensor, I may go custom with slim fans, or get creative with them. Anyway, onto the pics, let me know if you have any questions.

Passenger Mount:

PS Pulley Clearance:

Rear O2 Sensor Clearance:

Power Steering line misalignment:

MX3 Front Bracket with P5 Mount:

P5 (Left) vs. PGT (Right) Shifter Arm:

Shifter Bolts/Bushings, P5 (top) PGT (bottom)

What we used with the stock P5 Shifter:

PGT Sleeve compared to P5 bushings:

Showing off the final product of PGT/P5 hybrid shift linkage (click for video):

 

[Lewis7789]

Chris, thanks for taking pics and measurements of the shift linkages. I greatly appreciate it, mate! Looks like I'll go to Pull-a-Part to snag one soon. I'll get some video of my shift pattern before installing the PGT linkage just for future reference on other P5/Protege KL swaps.

And I'm glad you got those motor mounts figured out and everything is starting to line up better.

 

[FORZWIN]

No worries, but you know that high quality video production I made is what did it for you

 

[Rockin03mp5]

Woot! Good progress. That engine looks so good in there.

 

[Lewis7789]

I keep forgetting to get the H pattern video. Tomorrow I'll get some, I promise. And yes, that video of your stock shift lever is so hot. More please. haha

 

[MadBiker]

Forzwin.... all I can say is Wow!!! Great progress... haven't been online here in a while... Can't wait 'til your finished!!!

 

[Lewis7789]

Hey Chris, I snatched a PGT shift linkage from the junkyard yesterday and installed it. Hallelujah for the correct shifter location once again! I owe you man, thanks a ton for measuring those linkages for me (us). (2thumbs)

 

[Slotege5_2003]

I'm about to tackle this project as well. I just recently bought a P5 to replace my probe that I already swapped a ZE into. Since I already have the full car as a donor and a complete swap is there anything else I need to worry about?

BTW....I love what you are doing with this car. SUBSCRIBED!

Oh, and Lewis.....I have followed your car on Probetalk for awhile now. I'm a huge fan.

 

[FORZWIN]

Forzwin.... all I can say is Wow!!! Great progress... haven't been online here in a while... Can't wait 'til your finished!!!

Thanks for the kind words. You and me both...

Hey Chris, I snatched a PGT shift linkage from the junkyard yesterday and installed it. Hallelujah for the correct shifter location once again! I owe you man, thanks a ton for measuring those linkages for me (us). (2thumbs)

Glad to hear it worked out for you and that I was able to give back a bit.

I'm about to tackle this project as well. I just recently bought a P5 to replace my probe that I already swapped a ZE into. Since I already have the full car as a donor and a complete swap is there anything else I need to worry about?

BTW....I love what you are doing with this car. SUBSCRIBED!...

Thanks for the support! If you already have the ZE working in the Probe, then you should be good to go. You're still going to need the tach signal converter from dakota digital. But off the top of my head, the only potential issue I see is the probe wiring; not many of us here are using ford electrics and all of the colors are different so it may be a bit more involved for you. I'm sure you'll take the time to look into replacing your clutch and maybe upgrading a few things in the process. Be sure to start a build thread to track you progress, the more information we have, the better. A couple of pointers, you'll want to use all of the protege mounts and engine mount bracket, and will end up making a hybrid linkeage between the probe/p5 in order to help your shifter sit correctly. You P5 axles will work just fine with the Probe Intermediate shaft so that should take care of the drive-line. You can also use your probe radiator/fan setup as well as the power steering system. It's your call, you can keep the P5 resevoir and lines, but since you have a doner probe, just use it's system so you're not battling with all of the lines and junk. Let us know if you have any questions, we'll try to help as much as possible.

 

[Slotege5_2003]

I haven't heard of the tach signal converter. More info please. What about A/C? And can I not just use the probe engine wiring, and the P5 body harness with both ecu's? Thanks for the help.

 

[Joost27]

Tach adapter I use and I think the other guys are using as well, cheap, works great, easy to wire up. You need this because the signal from the v6 disty is not the same as the 4cyl tach signal so if you want a working stock tach. this is the solution.
http://www.dakotadigital.com/index....tegory_id=287/home_id=59/mode=prod/prd127.htm

A/c can be retained, with a bit of work. It is one of the parts of the swap I am not willing to go into detail on, for the main reason, I need to have something most do not

 

[FORZWIN]

This weekend I got a few more goodies. Brian cut me a deal on a few of his parts since he's planning to go back to stock. Sunday we removed his Spool springs and mostly worked to get it road worthy since his was the only P5 leaving the garage that day . In short, I aquired his spool springs and a set of Rota Slipstreams that came with his car. I've always like the look of his car with that wheel and suspension setup and am pretty stoked to have these parts on the Passion5. I was concerned as to if/how the slip's would fit over the MZ6 brakes up front, but it all worked out! Brian's car took up most of the day, but I was able to get the front springs on and get my driveshafts installed.

I had my rear manifold welded up, had to move the O2 sensor and block off the EGR tube, installed that and it fits a lot better. I love that I can install the manifolds from the top I have to have the front manifold modified as well, the O2 sensor is hitting the fan shroud in the front and while I could run different fans, it's still in a bad spot.

Hopefully this weekend I can get some time to put the rear suspension on and get the car on the ground again. The coolant neck (below distributor) is not fitting, it doesn't line up with the mount hole, so I'll need to re-weld the bracket. Other than that, I'm just trying to get it put together so I can start on my wiring. (pictures coming)

 

[FORZWIN]

I haven't heard of the tach signal converter. More info please. What about A/C? And can I not just use the probe engine wiring, and the P5 body harness with both ecu's? Thanks for the help.

You can use the probe engine harness and run two ecu's, so long as you're tracing the wires yourself. Most of us are running mazda engine ecu's and harnesses so the colors are different and won't be exactly the same as yours.

...A/c can be retained, with a bit of work. It is one of the parts of the swap I am not willing to go into detail on, for the main reason, I need to have something most do not ...

...secrets don't make friends.

 

[Joost27]

You can use the probe engine harness and run two ecu's, so long as you're tracing the wires yourself. Most of us are running mazda engine ecu's and harnesses so the colors are different and won't be exactly the same as yours.



...secrets don't make friends.

lol i know, but i am willing to help with anything else to do with the KL in protege.

 

[Slotege5_2003]

I'm confused. Are you putting a blower in its place? Either way I have no doubt in my mind that it can and will be done.

 

[Joost27]

what about a blower?

 

[Slotege5_2003]

In place of your a/c. Clutched M62 perhaps?