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Discussion Starter #41 (Edited)
Well... yesterday I was finally able to hook up the tranny harness, install the master cylinder and reservoir, connect the hydraulic line, plug and reconnect everything under the dash and find out if my splicin', cuttin' and adaptin' had a happy ending.

I located the "back-up" and "neutral" wires on the auto harness and connected them to the corresponding switches on the 5 speed.

I left the range sensor connected to the loom, but out of all the wires coming out of the connector, only two ended up staying actually connected directly to the ECU, since four of them were cut and routed to the switches.

The wires left on the range sensor are (I assume) signal back to the ECU about lever position (Back-up and neutral are not "signal", just on/off switched positions, I'm guessing as using the switches, instead, did work)

No clutch switch installed yet, I might also install it after all, you can see the plug and connector on the pictures, the plug jumps two pairs of terminals, indeed.

The starter did turn!! :smile2:

... ... :frown2: but stupid me, overlooked one simple thing: The gears in the 4.6 and 3.8 starters are not the same diameter. Both do work with 164 tooth flywheels (or flexplates) but the 4.6 one is considerably larger than the 3.8 (about 7mm difference!!) ... So the gear I used in my "frankenstein" starter (being bigger than the one originally used with this starter faceplate) hits the flywheel "face" rather than going all the way out to engage the teeth... no biggie, I'll try and switch the gears tonight (hopefully they will switch) ... if not, I'l have to think of a way to separate the starter from the flywheel about 3.5mm.

Regarding the shifter, as you can see on the picture (that's first gear) I'll have to fix that. As you know, the dashboard in 94-97 cars is a couple inches more to the rear compared to earlier years. That was also overlooked in my calculations :crying:) ... I will have to use a 2.5' long x .5' thick steel plate to move the shifter back. :|

Being stubborn has its downside, I guess...:frown2:

Still, I'm enjoying this process a lot.
 

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1994 Cougar XR7 DOHC/5-Speed
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Actually the shifter placement is likely the fault of the 4.6 engine placement/dimensions vs. the V6. The M5R2 didn’t dimensionally change for 1994, nor did the trans tunnel opening and boot plate, so the 4.6 must sit further forward., moving the trans ahead with it.

Really interesting about the factory clutch switch being there. That would have made things easier for me on mine :tongue:
 

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Discussion Starter #43 (Edited)
Actually the shifter placement is likely the fault of the 4.6 engine placement/dimensions vs. the V6. The M5R2 didn’t dimensionally change for 1994, nor did the trans tunnel opening and boot plate, so the 4.6 must sit further forward., moving the trans ahead with it.

Really interesting about the factory clutch switch being there. That would have made things easier for me on mine <img src="http://forums.tccoa.com/images/smilies/vb2_tongue.gif" border="0" alt="" title="Tongue" class="inlineimg" />
Now that you mention it, I now recall @Ty Whutaker saying something on his thread about the 4.6 sitting "an inch or two" forward (compared to the 3.8 that was on the car before his swap) ... And, yes... I had to turn the hole (on tranny crossmember for the rubber mount) into a slot… long enough to accomodate the new forward position of the tranny, you're right.
 

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Discussion Starter #44
Bought a new starter gear today, the smallest I could find in parts stores.

Box says it's for a Ford Ranger.

There was a 7mm difference between the gear I needed to use with my "Frankenstein" starter (25mm) and the one I was actually using (32mm), the one I got is 28mm and 10 teeth.

I'm crossing my fingers now hoping clearance issues are over and the teeth will engage this time... it will actually be a 1.5mm problem if they dont!!... in that case, I'll have no choice but to move the starter outwards somehow a meager 1.5mm :|
 

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As long as they are the same pitch, it should be all good; if not, it will grind everything to match in short order. :)
 

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Discussion Starter #46 (Edited)
As long as they are the same pitch, it should be all good; if not, it will grind everything to match in short order. :)
:grin2::grin2::grin2::grin2:

The picture makes it look like the gear on the right has quite a different pitch than the new one on left, but the new one is just closer to the lens and that made it look same size as the old one but with a different pitch.
 
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