NEW Project 2 2004 Connect T200 LX (Pic Heavy)

[paul2012]

Sorted handbrake problem

2009 onwards lever with the original 2004 forward section of hanbrake cable.
As you can see the 10mm adjustment nut is wound all the way down & can't go any further.



Removed lever & old cable, - No need to go underneath. Once rubber grommet is removed, it gives you clear access to release cable from rest of assembly



Here you can see the difference in lengths between the 2003-2009 (top) & 2009 onwards cables.



Handbrake lever & new cable fitted - now adjusted & working perfectly

[paul2012]

Oh well, trouble getting hold of new rear brake pipes (ABS) Ford can only get NON ABS ones

So a trip to local breaker picked up a pair from a 2006 connect for a £5
Unfortunately I can only use the O/S rear pipe, that is fairly clean - mostly covered up by fuel tank & spare wheel. so that went straight on.







N/S one is no good (MOT failure - excessively corroded)





I ordered a non ABS N/S rear hosefrom Ford, which runs from unions just in front of fuel tank to LSV - I was Surprised to get a pair for £12
Placed along side the ABS pipe to see if I can use it. Sure enough the forward part is the same.





Cut sown to size & slight alteration, fit new end then installed it - job done



I now require the Last forward section of brake pipe from ASB pump to first union above steering rack for rear middle section. Unfortunately Ford don't supply.

[Altransit]

Why not just get a copper pipe made up at a motor factor

[paul2012]

Why not just get a copper pipe made up at a motor factor

They require the old one to make up a new one too. Unfortunately I don't have the old pipe from ABS pump from a 2009 onwards connect

[paul2012]

Fitted 2 brackets for ABS wheel sensor wiring to O/S front & lower cover for Aux drive belt.



Also removed wing to mount the ECU



Refitted wing, Arch trim & wheel well liner.

[paul2012]

New drivers seat belt clasp/buckle arrived today

Connects to airbag module & turns off seatbelt warning light (also the chime) on instrument cluster when you put your seat belt on.
Fitted to connects from 2009 onwards

[paul2012]

Fitted new side trims today. These are from Ford & are handed (RH/LH)
I'm going to colour code all door handles



New cover for jack etc. when I do get round to plyboard the rear, I will cut a window then Jack etc can be stowed away properly



Finally New N/S driveshaft has arrived, now I can get on with fitting N/S front ABS hub at the same time.

[paul2012]

Today fitted new N/S drive shaft & ABS hub, Waiting for last front ABS sensor wiring bracket to arrive



Also small brackets for rear ABS sensor wiring have been fitted on both sides

[Lennie]

liking this , your a clever fooker...

[paul2012]

liking this , your a clever fooker...

Thanks more updates to follow

[paul2012]

Update on progress of patching in the 2009 onwards equipment onto the 2007 dash loom
Currently still working on it, here's the start.

Started at the instrument cluster plugs, first thing was the label every single wire on both of the 2007 instrument cluster plugs. (Full wiring diagrams are very handy for this job )



Then did the same to the 2009 onwards cluster plugs.



Instead of cutting & joining wires, I removed the pins from the 2007 plugs & refitted in the correct locations to the 2009 onwards plugs



This what it looks like when that part is done. Not all wiring at the 2007 plugs is fitted to the 2009 onwards ones.
Wiring not used by the 2009 onwards instrument cluster have to be chased back through the loom. All the way back to Fuse panel & plugs that connects to engine bay loom through bulkhead.
As they are connected to GEM module instead .
There's extra wiring required for 2009 onwards cluster to column controls for example menu buttons etc & also low/dipped beam interrupt relay has to be added.



Now the Boring Tech Info bit

This will apply to dash wiring looms on connects from 2006-2009

Following wiring already present on 2007 cluster plugs & now fitted to 2009 onwards instrument cluster plugs at the correct pin locations

VBAT J2-1
V IGN J2-6
V ACCESSORY J1-14
GND J2-2
HANDBRAKE / BRAKE FLUID LEVEL J2-7
ILLUMINATION J1-24
BRAKE PEDAL SWITCH J2-19
ACCELERATOR PEDAL 5V+ J2-12
ACCELERATOR PEDAL INPUT J2-18
ACCELERATOR PEDAL GND J2-13
CLUTCH SWITCH J2-20
FUEL GAUGE SIGNAL J2-14
FUEL GAUGE RETURN J2-15
PATS RX/RX J2-26
PATS TX/TX J2-25
HS-CAN HIGH J2-23
HS-CAN LOW J2-24
MS-CAN HIGN J2-21
MS-CAN LOW J2-22

The following wiring not present on 2007 dash loom & is required to be patched in for 2009 onwards instrument cluster & column switchgear
AMBIENT AIR TEMP (OUTSIDE TEMP) IN J2-17
AMBIENT AIR TEMP (OUTSIDE TEMP) OUT J2-16
HIGH BEAM RELAY J1-7 NEGATIVELY OPERATED (2007 RELAY IS POSITIVELY OPERATED - MOD REQUIRED)
LOW/DIPPED BEAM INTERUPT RELAY J1-8 (NOT PRESENT ON 2003-2009 CONNECTS)
MENU DOWN J1-20 CONNECTS TO INDICATOR STALK/COLUMN SWITCHGEAR
MENU UP J1-19 CONNECTS TO INDICATOR STALK/COLUMN SWITCHGEAR
MENU RESET J1-21 CONNECTS TO INDICATOR STALK/COLUMN SWITCHGEAR
HIGH BEAM FLASH/PASS J1-2 CONNECTS TO INDICATOR STALK/COLUMN SWITCHGEAR
HIGH BEAM J1-2 CONNECTS TO INDICATOR STALK/COLUMN SWITCHGEAR
AIR RECIRC J1-18 CONNECTS TO AIR RECIRCULATION SWITCH

Wiring on the 2007 instrument cluster plugs NOT used on 2009 onwards clusters & are connected to GEM module instead
HEATED FRONT SCREEN RELAY & SWITCH
HEATED REAR SCREEN/MIRROS RELAY & SWITCH
INTERIOR LIGHT RELAY
BATTERY SAVER RELAY
INTERMITTENT FRONT WIPER RELAY & STALK/COLUMN SWITCHGEAR
REAR WIPER RELAY & STALK/COLUMN SWITCHGEAR
FRONT/REAR WASHERS & STALK/COLUMN SWITCHGEAR
LH/RH INDICATORS & STALK/COLUMN SWITCHGEAR

Wiring no longer required
AIR BAG (warning light)
ABS (warning light)
HIGH BEAM (warning light)

[paul2012]

Decided to fit a new rear heat shield as original one was missing







To finish the rear, colour code rear door handle & bumper.

[tez]

that's what is missing off my back axle ?

[Trender]

that's what is missing off my back axle ?

Heat shield or stabilizer ? Tez

If its the stabilizer I've just checked my 2013 and mines missing as well... is that ok or should it be there ?

[tez]

that's what is missing off my back axle ?

Heat shield or stabilizer ? Tez

If its the stabilizer I've just checked my 2013 and mines missing as well... is that ok or should it be there ?

the stabilizer m8