This conversion is not as easy as some people make out but can still be done by the back yard mechanic with some basic skills. You will need: Type 9 gearbox from a Sierra 1600 (about 1988-92) Bellhousing to suit the Pinto 2000 engine 20mm thick spacers to go in the cross member mounts (optional) Clutch, flywheel, pedal box, clutch cable, etc.
The cross member off the automatic transmission fits the Type 9 but needs to be lowered 20 mm otherwise the g/box will hit the underside of the transmission tunnel.
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To begin, Remove the Negative battery cable, your throttle body cover, and intake and set them aside. Using your fan clutch removal tool, or wrench and screwdriver, remove the nut holding the fan to the water pump. On the Sport Trac it is standard right hand thread. Once it is off, be careful not let it hit the radiator, or this could cause damage. Now remove the 2 10mm bolts holding the fan shroud to the radiator. Now remove the fan and shroud as 1 piece. Once removed, there should be a nice sized gap in your engine bay.
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Subject: Starter motor Failure
Model: Ford 2.0 TDCI FWD & 2.4 TDCi RWD/2.0 TDCi FWD
On inspection, the units do not exhibit any manufacturing defects. The premature failure of the unit is due to contamination of the pinion/drive area from metal dust particles produced within the Dual-mass Flywheel, when the clutch wears or becomes overheated. During scheduled servicing, it is recommended that the clutch is checked and if found to be showing signs of wear should be replaced.
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This bulletin supersedes TSB 06-40-005 to include a procedure for GDS. CAUTION: Before replacing a transaxle to improve a shift quality condition, follow this procedure to reset and relearn the adaptive learning.
DESCRIPTION: The PCM or TCM contains logic to adjust solenoid duty and line pressure as needed to compensate for normal clutch wear over the life of the transaxle. This bulletin provides the procedures necessary to reset (erase) and “relearn” the PCM/TCM adaptive values. After the following repairs have been completed, the PCM/TCM adaptive values must be reset in order to provide optimum shift quality:
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To increase the durability of the clutch in 2.4L manual transaxle Santa Fe vehicles, the Dual Mass Flywheel and its components may be replaced with the Single Mass Flywheel (SMF) system in accordance with the applicable Shop Manuals’ replacement procedures.
AFFECTED VEHICLES: All Santa FE (SM) 2.4L vehicles with manual transaxles produced through July 16, 2003.
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Some vehicles may exhibit clutch chatter or judder when releasing the clutch during cold conditions. This concern may be caused by the clutch surface materials creating a chatter or judder during clutch engagement. Customers experiencing this concern should have their vehicle repaired using this repair procedure.
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Shift linkage, adjusting Transmission in neutral Loosen clamp (arrow). Joint between selector rod and selector lever must move easily Remove shift knob, boot, and frame => page 34-21. Insert gauge 3104. Gauge must not jam Align selector rod/selector lever (with transmission in neutral) and tighten clamp. CAUTION! DO NOT put components under stress. Operation Selector lever resting in 3rd/4th-gear plane with transmission in neutral Shift through all gears. They must engage smoothly without hanging up. Pay particular attention to correct operation of the reverse lockout. If a gear fails to engage smoothly during repeated shifting: Engage 1st gear. Remove play from shift linkage by pressing (more…)

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Volkswagen > A3 Platform > 1993 – 2002 5 Spd. Manual Transmission 020 34 – Manual Transmission – Controls, Housing Clutch housing, servicing 1 – Oil drain plug Without magnet 25 Nm (18 ft lb) 2 – Dowel sleeve Qty: 2 Shim S2 Always 1 mm thick (0.04 in.) 4 – Outer race of tapered roller bearing for differential Removing and installing => page 39-5 When replacing: adjust differential => page 39-17 5 – Magnet Retained in housing joint surface Install with AMV 188 200 03 sealant 6 – Shim S3 Adjustment summary => page 39-16 7 – Outer race for output shaft tapered roller bearing Removing and installing => page 35-14 When replacing: adjust output shaft => page 35-27 8 – Needle bearing for input shaft Removing => Fig. 1 Installing => Fig. 2 9 – Bolt With locking teeth 25 Nm (18 ft lb) 10 – Relay lever 11 – Spring 12 – (more…)

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1. Before servicing the vehicle, refer to the Precautions section. 2. Remove or disconnect the following: • Negative battery cable • Transfer case, if equipped • Transmission 1 • Pressure plate. Loosen the bolts evenly in /2 turn steps. • Clutch disc To install: 1. Install or connect the following: • Clutch disc and pressure plate. Tighten the pressure plate bolts evenly in /2 turns to 23 ft. lbs. (31 Nm) for 2.4L and 2.5L engines; 37 ft. lbs. (50 Nm) for 4.0L engines. • Transmission • Transfer case, if equipped • Negative battery cable
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The following procedures for removing the fan clutch gives the factory recommended loosening and tightening directions for the fan hub nut. However, it has been our experience that certain aftermarket parts manufacturers have changed this to enable use of universal fit parts. We recommend trying the factory direction first, then, if the nut doesn’t seem to be moving, reverse the direction. Placing too much load on the water pump snout will break it.
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