240sx to 500sx conversion (5.0 H.O. swap in progress)

[lost cause]

Ok so here is the build thread, most of the actual engine work is going to happen this weekend. Should be getting my harness in, get the steering rack swapped over to one with the mounts pre-fabbed, and possibly get the motor in the car. Here is the car as it sits, minus the exhaust and interior

http://i57.photobucket.com/albums/g213/srt8u/240sx%20build/DSCN0305.jpg

http://i57.photobucket.com/albums/g213/srt8u/240sx%20build/DSCN0304.jpg

The motor going in is a 1993 5.0 H.O. with shortie headers, though the drivers side needs modified to fit around the steering shaft.

I am probably going to go catless, to dual mufflers, out the same side of the car where it originally exited

I am considering running a mega-squirt setup though I don't know much about them and not sure if I really need it for a mild build setup.

Parts I still need: (if you have these pm me with what you want for them)

93 gauge cluster, and dash harness

93 T-5 compatible drive shaft ( just need front half so I can merge with rear of 240sx shaft)

Radiator for 5.0 engine (might go new, depends on what I can get)

T-5 short shifter

AC compressor eliminator

pulleys for 5.0 engine

Also wouldnt mind help installing the harness and working on it in general... if your feeling helpful or bored, come hang out, and drink some free beer. My shop is in Harveysburg, OH.

[93snake]

Looks like an interesting project

[1992MustangDW]

i have tons and tons of research about this. had a few buddies with 5.0 240's

[lost cause]

i have tons and tons of research about this. had a few buddies with 5.0 240's

Did they go EFI or did they carb them? I'd be real interested to get some tips and stuff from the guys who went EFI..... When I get the car running and know everything is as it should be, a HX35 turbo or something of the sort WILL follow lol..... I want to sit right around 350hp and call it done.

[bkstang95]

Very cool project!

[setty2706]

That will be a fun driver....... hope the swap goes smooth..

[blown96cobra]

I think I have a drive shaft lying around. I just put new ujoints in it before I switched to an aluminum one. $20 picked up if I can find it.

[lost cause]

not sure If I need the u-joints or not, but I will see if I can pick it up from you next week. I plan on having the motor in sometime next week so I will need to get the driveshaft measured and marked for the adapting to the 240sx rear end.

[lost cause]

more progress.... (actually got the car on jack stands now)

heres the pics of where I am at...

engine bay in need of paint before engine goes in.... still have some minor things to remove (namely the old crossmember)
http://i57.photobucket.com/albums/g213/srt8u/2011-06-03_21-22-26_799.jpg

http://i57.photobucket.com/albums/g213/srt8u/2011-06-03_21-22-15_849.jpg

crossmember that is modified to fit the motor in the car

http://i57.photobucket.com/albums/g213/srt8u/2011-06-03_21-22-54_513.jpg

wiring harness.... ugh this is where it gets scary

http://i57.photobucket.com/albums/g213/srt8u/2011-06-03_21-22-46_736.jpg

The beast itself..... surprisingly almost as light as the iron block 4 cylinder motor that came out.... in fact with the automatic bolted to the 4 cylinder motor, they should have come out within 30 lbs of each other

http://i57.photobucket.com/albums/g213/srt8u/2011-06-03_21-22-38_513.jpg

the shortie headers I got with the car.... debating modifying them to work on the drivers side.... may trade for a set that will fit, let me know if you got some block huggers, or wanna trade some stock ones and cash

http://i57.photobucket.com/albums/g213/srt8u/2011-06-03_21-23-34_848.jpg


I'm going to try to have the harness in tomorrow, and also the crossmember..... if things go well, the motor will be in the car on Sunday....

[Jake]

looking good.

[85_SS_302_Coupe]

I'm thinking you would have a much easier job modifying unequal length shorties rather than those spaghetti knot equal lengths.


Oh and i mentioned this to a random semi-car knowledged coworker, and he went on to tell me how superior the "23LK3H whateverthefuck" engine is to the 5.0 and how this was a step backwards LOL. When those import kids start spouting off numbers and letters for engine names, my mind tends to wander.


Oh and as for weight...that's not surprising. A lot of the Merkur guys are swapping in 5.0s now because there's only about a 75lb difference between them and a turbo 2.3 with a big intercooler and all the plumbing.

[lost cause]

the ka24de that was in there can hold about 250hp on average before it becomes unreliable.... some people have went higher, but the avg is 250.... a SR20DET (japanese engine for this car) is turbocharged and can handle 350+.... Problem is you typically get one in bad shape, or abused and have to rebuild it, etc.... and torque sucks....

By the time I have this thing done, I will have less money in it than it costs to put the SR20 in this car.... avg swap price for the SR is $1500 for the engine, then you have to buy the clutch, rad., intercooler, bov, driveshaft..... total price would end up around $2200..... I will have about $1200 with everything by the time I am done..... Its all about catching people who start a project and cant afford to finish it....

I ended up getting this motor set with mounts and all for less than $500.... The motor has already been test fitted in a 240sx, and all mounts and fab work is already done except the header.... I have a friend who builds custom choppers so thats an easy one. The driveshaft is the only thing I have to pay to get done, because I want it done in a single piece, and I want it PERFECT..... When this car is done I'd like to see an SR20det boy try to hang with me..... not gonna happen without having at least 3x what I will have in this thing.... and I will still be able to drive it every day without having to check the oil....

[satan jamez]

Very cool project and a sleeper if you keep it quiet enough. Nice power to weight ratio should make this car shit and get pretty good.

What do these ares typically weigh stock?

I love the bumper sticker too! Go Contra :)

[chris91]

If you need a set of stock headers I have a pair you can have. Just gotta make sure they havent been scrapped yet.

[lost cause]

my car weighed in at 2700 lbs and some change (cant remember exactly but was on low side ) before I completely gutted it.... Putting a full cage in it should raise it back up to around 2700-2800 lbs....

chris91, if you still got em, I would definitely take em!

[chris91]

Sorry man, just check with my buddy and he scrapped em YESTERDAY.. Day late and a dollar short, story of my life. lol Im sure someone else on here would have a set layin around though.

[mad max]

I have a set of stock headers i would trade you for yours .

[lost cause]

sounds good bro... just come down tomorrow to the harveysburg Jeep jam if you can and I will swap you.... I guess stockers clear just fine for whatever reason!

[89johnny]

Great project dude. Ive had four 240sx's three with ka and one with sr20 and my gently modded 5.0 mustang would beat all of them. So imagine how the 240 would run with a 5.0 in it! I was always interested in this swap and im dying to see how it turns out. Keep us posted man

[mad max]

Can you pm me your number ?

[lost cause]

done.... I am going to work on it today, we will see how far I get....

[Moody]

if you still need a shifter i got a B&M on a T-5 im trying to get rid of.

[Stangman]

The vocational school out by me build one of these... don't remember too many details though

[lost cause]

I found a shifter down in the bottom of the wiring harness box so apparently I have one, though I need the shift rod and knob now... all I have is the part that mounts to the transmission.

Thanks to Mad Max I was able to get the stock headers, so now that issue is gone... He got a free set of shortie equal length headers out of the deal so it worked out good for both of us....

I picked up a bunch of sheets of stainless steel for fabrication purposes, and also came upon a crap load of stainless high pressure lines.... If anyone is interested in them I may let what I don't use go cheap :bigthumb

[mad max]

Definetly worked out good for both of us. Nice to meet you jeff , if you need anymore parts , just ask.

[lost cause]

yea it was nice meeting you too, I was super busy yesterday and you showed up right on time.... I haven't even had a chance to inventory all the stainless lines I got from work

[lost cause]

sorry for the lack of updates lately, got motivated today, and got the crossmember swapped... I need to go buy some rack bushings, the ones on this car are shot bad.... think cooked spaghetti noodle, when it should be solid like a tire.... Gonna go buy a dremel to cut the firewall for the grommet.

here is the old crossmember ..... mmmm greasy
http://i57.photobucket.com/albums/g213/srt8u/2011-06-19_13-41-15_295.jpg

here is the rack sitting waiting for the new crossmember to be mounted

http://i57.photobucket.com/albums/g213/srt8u/2011-06-19_13-41-03_984.jpg

here are all the high pressure stainless braided lines I got for free :D

http://i57.photobucket.com/albums/g213/srt8u/2011-06-19_13-41-28_893.jpg

[9cobra4]

This should be cool project, just please don't do a bunch of the ricer stuff these people do to these cars..IE: Negative camber, 205's on a 10" wheel, dildo shift knobs....:lol:

[lost cause]

nah this car is 100% functional.... camber will be 0 and so far I plan on running 245's on the 9" rim

[Jake]

This should be cool project, just please don't do a bunch of the ricer stuff these people do to these cars..IE: Negative camber, 205's on a 10" wheel, dildo shift knobs....:lol:

I think we have seen the same cars running around. I have seen three in my life and they were all together. :confused:

[flybye]

Looking good buddy....hit me up anytime if you need help. I will be posting my build thread on here too. (Doing the same swap for those of you who don't know)

[furiouslyfaster]

The vocational school out by me build one of these... don't remember too many details though

I remember that car Jesse!

As far as the build goes how is it coming?

[satan jamez]

Dildo shift knobs for the win! lol, funnest thing i've heard all day.

[DNTRYIT]

Interesting build and great progress cant wait to actually see the car finished!

[phatford]

my cousin did this swap in nashville. If I can find the link on it I will post up his build.

If I remember right he used convertable motor mounts from a 240 and the 5.0 sat on it perfectly...i will find the link

[angsears]

cant wait to see it done

[foxbody]

gonna be a sweet ride. definately a head turner when the exhaust rumbles instead of buzzes.. keep up the good work.

[lost cause]

Long time no talk, the lack of updates can be attributed to my divorce :flipoff:

I have my Hydraulic throwout bearing, rack bushings, and Wilwood master cylinder now... Motor will probably go in next week :bigthumb

All that I need to do is nudge the transmission tunnel out of the way, then it should slide in.


PARTS I STILL NEED:

93 5.0 driveshaft (need the front piece only, doesnt matter if u-joints are bad)

Radiator (might be able to use a mustang one, let me know if you got an old one that I can test fit)

Power steering bracket (I have a new PS pump, need the bracket)

Power steering High pressure line (from a 93 5.0

Let me know if you have anything I could use!


I promise, pictures are coming soon.

[furiouslyfaster]

Still interested to see how this build is coming were are those pics you said are coming soon lol. J/K Sorry to hear about your divorce. Never gotten one but heard they suck.

[lost cause]

I will get some pictures this weekend, I might actually get to do something to the car.... Been so busy, on top of that my kids have been sick, and motivation was also low. Met another guy last weekend who had already completed a swap like this from Indy, and he had his supercharged.... I will try to find pictures of it, because the way he had the car set up, it looked like a stang.

[lost cause]

No updates yet, part that was supposed to show up, didn't show up, should be here tomorrow, which will mean I finally will have progress on the car again. Im shooting to have the clutch pedal, master cylinder, and trans tunnel hammered in by Tuesday.

I'm having to do alot more work, because this car was a non-abused Automatic, so I have to add a clutch pedal, and stuff to it. Its semi-easy because Nissan used the same firewalls for the auto and manuals, they just didn't drill the holes for the clutch assembly to mount up.

[lost cause]

Ok small update, finally wasn't sick, didn't have the kids, and had some motivation to work on the car....

I got the new Energy Suspension poly steering rack bushings put in..... what a pain.... Also got the dash removed so that I can get the Clutch master cylinder installed, and pulled the factory cluster, since it will be replaced with a load of gauges..... much easier than modifying a Mustang cluster to fit in the factory hole.

Only have one picture, which my brother snapped of me, while I was under the car cranking on the steering rack

http://i57.photobucket.com/albums/g213/srt8u/309464_2550914095099_1321268675_2945783_1964212868 _n.jpg


Gonna work on it again tonight, and hopefully get to installing the motor by Friday if I can....

[heyitsmepugsley]

cant wait to see pics of the motor down in the car.

[setty2706]

Glad to see your making progress.... I am with pugsley i cant wait to see the pics of the engine in that car... That will be a fun street toy

[INSANEBA]

I've had S-10's and Rangers with v8's in them and had an absolute blast with them. I've always wanted an import car with a lumpy ass v8 in it, so I'm enjoying the hell outta this thread. Cant wait to see the finished product!

[Moody]

looking forward to see this thing running... its kinda like a monster miata but cooler cause its not a miata.

[cyah92]

Nice build u r deffintly on a mission

[lost cause]

Finally got the engine hoist over to my house, and got the transmission off.... figures, one of the starter bolts was rounded off, so I had to cut the head off and pull the bolt out the hard way....

http://i57.photobucket.com/albums/g213/srt8u/photobucket-4446-1326059469742.jpg

The transmission could use some cleaning in here lol... Its ready to be disassembled so the hydraulic stuff can go on

http://i57.photobucket.com/albums/g213/srt8u/photobucket-11718-1326059486933.jpg

My guess is, this is what is left of the clutch disk.... and misc debris, though it cant be from outside, because the transmission was sealed to the motor quite well....

http://i57.photobucket.com/albums/g213/srt8u/photobucket-15729-1326059498757.jpg

Saving space in the garage for the night, the motor is sitting in the bay... its still off about 1 1/2" from its final position, but I still have to get the clutch off and removed, as well as get some bolts to stick in the header bolt holes so that I can drop the motor in the right way...
http://i57.photobucket.com/albums/g213/srt8u/photobucket-15168-1326059556875.jpg

Shows how it is sitting without the transmission on the back, and a little high.... there is so much room around the motor, I am really surprised how small this motor looks in the car.

http://i57.photobucket.com/albums/g213/srt8u/photobucket-11911-1326059541247.jpg


I kinda cracked the starter flange (where the upper bolt goes) when the starter wouldn't come out, seems it was seized in there pretty good, dunno why though, it works fine.... Are they pretty cheap? Should I replace it, or should I try fixing it?

Sorry for the lack of progress in the last couple weeks/month I have been slacking quite a bit.

The motor is not in its final position, because I am going to order a new clutch and then reassemble everything.

[lost cause]

Ordered my King Cobra Clutch kit for it tonight.... looks like I will be able to put this thing back together very very soon..... All that's left is...
--------------------------------------------------------------------------------
1. Install clutch kit
2. Install Hydro T/O bearing
3. re-mount transmission on engine
4. Install engine and transmission
5. Make adapter for shifter relocation
6. Wire up motor to 240sx body harness
7. Install gauge setup (still pending on if the ARK MFD will work with this motor)
8. Measure and have driveshaft made
9. Buy radiator and mount
10. Put fluids in, and drive.
---------------------------------------------------------------------------------

Still alot left to do, not including putting a cage, and racing seats/harnesses in.... As well as taking the bald rear tires off and having more tires put on.

[lost cause]

Radiator and clutch arrived....

All aluminum Radiator
http://i57.photobucket.com/albums/g213/srt8u/photobucket-12942-1327517071702.jpg

King Cobra Clutch with new pilot bearing, throwout bearing (don't need it)

http://i57.photobucket.com/albums/g213/srt8u/photobucket-15793-1327517124570.jpg

I am getting excited :D

[lost cause]

Gonna have some major updates later tonight... I am currently working out how to install the RAM hydro throw out bearing, since my King cobra clutch pressure plate is touching the C clips, I guess I have to remove them, and then get my spacing right, and all will be done.

The motor is just a few minor steps from getting permanently mounted in the car.

[700hp04mystic]

looks good man, keep us posted with pics.

[blown96cobra]

man that looks like one hell of a tight fit

[lost cause]

here's some pics I snapped, my brother took most of the pictures, so I don't have all of them yet, but this is what I have.

I put a new rear main seal, and pilot bearing in. Didn't take pictures, didn't seem important enough to

I knew I needed a new clutch, the previous one was toast.... Here's what the flywheel looked like when I pulled it off.

http://i57.photobucket.com/albums/g213/srt8u/photobucket-18458-1328219110260.jpg

So I sent that off to get re-surfaced, because there was no way I was going to get away with fixing it myself....

Took it to Auto Value here in Wilmington and here is the result

http://i57.photobucket.com/albums/g213/srt8u/photobucket-3913-1328219162639.jpg

After a nice cleaning with brake parts cleaner, I installed the King Cobra clutch, and pressure plate. Everything went together pretty easily, and looks good installed.

http://i57.photobucket.com/albums/g213/srt8u/photobucket-5356-1328219400895.jpg

After all that fun stuff, I got started on the hydraulic throw out bearing. Its made by RAM clutches, and seems to be pretty solid. It was kinda pricey, but for a swap like this, it was necessary, as the 240sx is hydraulic to begin with, and swapping to a cable would require a different clutch pedal.

After removing the old clutch fork, and throwout bearing, then removing the pivot ball, and original center section (don't know what its called) I installed the RAM center section, that is made for the hydraulic T/O bearing to slide on, and putt the hydraulic bearing on there for measurements.

http://i57.photobucket.com/albums/g213/srt8u/photobucket-19106-1328219517980.jpg

This is what it looks like through the old clutch fork hole.

http://i57.photobucket.com/albums/g213/srt8u/photobucket-3157-1328219436340.jpg

All in all, it went pretty easy, though I have to talk to tech support with the bearing, because the instructions say to get the clearance down to .150-.200" and I am at .500" . Obviously I need to use some shims, but I want to make sure that I am doing everything 100% right. The other small issue, is the fact that the bearings C clip hits my pressure plate fingers, which means I am going to have to remove them, in order for it to work properly.

After I get this done - Possibly by tomorrow - The motor will be getting mounted into the car and the next step of the process will begin.

On a positive note, I did look up the transmission code, and it is a 1992 WC T5....

[lost cause]

man that looks like one hell of a tight fit

believe it or not, it actually doesn't look all that bad when your looking at it in person.... If your ever in Wilmington and wanna stop by and look for yourself, just shoot me a P.M. It always helps to have a mustang guy there to tell me what I am doing wrong :lol:

[Stangman]

That oil filter looks really close to that frame rail!! Lol

[lost cause]

That oil filter looks really close to that frame rail!! Lol

I think I am going to do a relocation kit on it.... your right in a sense, even though there is enough room to get it off, it sits a little too close to make me happy... I am going to get the engine in its final location, bolted up, and see if it is better or worse.... If it doesn't improve, I will be ordering more parts... :mad:

[lost cause]

a couple more pictures from today, got em from my brother, who stayed clean through this whole ordeal lol....

http://i57.photobucket.com/albums/g213/srt8u/76f45c4f.jpg

http://i57.photobucket.com/albums/g213/srt8u/4b3b18ec.jpg

http://i57.photobucket.com/albums/g213/srt8u/182562f8.jpg

just a few pictures of putting the Hydraulic T/O bearing on.... way more in depth than I originally thought.... the old sleeve held the race, which had to be removed, and relocated to the new sleeve, seemed the transmission is in pretty good shape.

[heyitsmepugsley]

we got some pics setty.lol

[BLOWN86CAPRI]

cool build,good luck with it

[lost cause]

Well my power steering bracket showed up today, waiting on a replacement radiator, since the one I ordered was measured without the end tanks, and didn't fit at all. New one is well within size requirements, and is actually a 2 core, so all I have to do is run a longer hose from the lower pipe to the right side of the car instead of the left, and all will be well

[5.0calypso93lx]

Curious to see how that hydraulic setup works out for you.

[90stang]

Looking good!!! did that driveshaft and pullys work out for ya??

[lost cause]

The driveshaft is going to work out great, I haven't gotten the measurement I need to cut it yet, but as soon as the motor goes in, I will send it off to the shop to get done.

I've been doing the last couple month's of this build from unemployment, since I was laid off in November, so my money has been short.... almost to the point where I considered selling it off.... But I have too many people telling me I won't finish the car to give up now... especially since its very close to being done.

I have heard very good things from another guy in California, that runs this setup on his 240sx, and all of his customer cars, so I have high expectations as to how its going to work.

[lost cause]

well I was pretty much ready to drop the motor in the car and ran into this problem... using the shims that I calculated based on the measurements they told me to take... the C clip hits the pressure plate fingers. Talking to Ram Clutches (T/O bearing designer) they say to remove the C Clip... Talking to the guy who has done this swap 10+ times now, he says there is no need to remove the C clip, that I just remove shims til it fits... So that is what I am going to do I guess... may require me to pull the motor once or twice, but at least it will be exactly the way I need it to be...

http://i57.photobucket.com/albums/g213/srt8u/photobucket-17259-1331955140968.jpg

[lost cause]

http://i57.photobucket.com/albums/g213/srt8u/541530_4365053767457_275137687_n.jpg

Motor is in the car. I had to cut out a new shifter hole location as the T-5 is shorter than the stock transmission. I am currently in need of a few more parts.....

I need

Alternator harness - I dont have one

Power steering bracket - The ebay model doesn't line my pump up at all...

AND lastly, I need someone that lives in Wilmington to drop by and tell me what some things are. There are a few things that I have that I have never seen and would like to know what they are and if I need them.

[lost cause]

Since I forgot to post it on here.... I just had to take that c clip off the t/o bearing and it fit great. I haven't bled the system yet, still waiting on getting everything together before doing that. The hydraulic setup looks factory now, really easy to do.

[2007ShelbyCobra]

where did u get your king cobra clutch? I believe i checked ford racing a few months back and it was no longer available

[lost cause]

I ordered mine from CJ pony parts. They had some listed on ebay, and I got mine quite a few month ago.... This project has been taking me a lot longer than planned since halfway through it, I lost my job, had to move due to renovations, and lots of other random garbage hit.

[lost cause]

Well I picked up a FRP power steering bracket and pump off of 93hulk last night, went to drive home, and my daily decided it didnt want to drink coolant anymore.... Started spitting it everywhere. Car overheated (nowhere to pull off in time) and shut off. Oil light, and check engine light came on.... Waited 30 minutes started the car up and it sounded like something was wrong.... 47k miles.... GM is going to fix it under warranty, but it makes me not want to buy GM cars anymore.

[TooFast98Cobra]

cool build, good luck with it!

[lost cause]

Thanks, I might actually get to work on it this weekend. Seems the daily has a Power steering leak (ironic since I picked up a PS pump for this car) and caused the radiator hose to soften/split.... Once I get that fixed, I will get back to work on this car.

Anyone know the size and pitch of the water pump pulley bolts?

[lost cause]

Great project dude. Ive had four 240sx's three with ka and one with sr20 and my gently modded 5.0 mustang would beat all of them. So imagine how the 240 would run with a 5.0 in it! I was always interested in this swap and im dying to see how it turns out. Keep us posted man

I am working on it, still need some guys to come over and help me out with a few things one night.... Would be helpful to have someone that knows mustangs around.

[lost cause]

Just a quick update on where I am with this.

I took the water pump off, and am replacing it, broke a bolt, had to take the timing cover off (what a PITA)..... As soon as I get that done, I can start putting the car the rest of the way together, and maybe, just maybe, get it started in the next month or two.

[lost cause]

Ok so some real updates for once....

I got my brand new water pump, found the bolts that hold the pulley on (5/16 -24 pitch in case your wondering.... no fan = less than 1/2" bolts)

I put a couple new bolts in the timing cover, put the front oil seal on, and got it all looking good.

I put the radiator in for the first time, just to test fit it.... hoses are going to be fun for sure.

http://i57.photobucket.com/albums/g213/srt8u/photobucket-119700-1352586925103.jpg

I took a picture of my shifter location.... Its a little forward from stock location, but not too hateful.

http://i57.photobucket.com/albums/g213/srt8u/photobucket-120903-1352586943656.jpg

I still have to get the right bolts for my Ford Racing power steering bracket, which I also noticed, the previous owner of this engine, took one of the alternator bracket bolts out for some reason.... so now I gotta buy 3 .

[Gongshow]

I've wanted to put one in a coupe. One day I will.

Keep us updated can't wait to see it run

[lost cause]

I'm currently trying to find someone that will make me a set of headers "cheapish" . The steering shaft is holding me back. If anyone knows someone that can do it reasonably, let me know.

[lost cause]

Well my wiring harness is at a shop in California getting re-built to be much simpler and easier to run. The company is Concept-8 http://concept-8.com/services.html.

For less than $200 he will take your harness, and strip all un-needed stuff out, label all necessary wires, and label what wires go to what gauge if you wanna run different gauges. I'll post pictures when I get mine back.