NEW Project 2 2004 Connect T200 LX (Pic Heavy)

[paul2012]

Estimated cost around £2900 to date,

Other than the 6sp box I have everything else now. so its build time

Althought once I've calculated the the price for the old parts that have been removed & sold & subtract it from the final cost.
For example old engine sold for £400 injectors went for £160 & several other bit & pieces have been sold - Still have loads of old parts spare like front & rear hubs, Rear axle etc all to be sold off.
I can honestly say what I claw back in parts sold gets put towards new parts

When complete & rest of old parts are sold, I think the total build cost will be just under £2000 (that's without the 6sp box)

Still a lot cheaper than buying a new one or even a second hand one

[Rumble bee]

Bargin

Lot of effort gone into this, are you keeping it or selling it when you've done?

[Big Jake]

Back to project again

Removed old wiring loom from engine bay



Also finally cleaned engine bay down, looks a lot better than it did before

love to no hw much this has cost u so far would ff be cheaper just to get new van as u not going to get your money bk what u hv spent on it are we

Not to mention the satisfaction of having created a one off van yourself, money can't buy that for most people!

Great project fascinating, keep it up.

[Graham Taylor]

Wiper arms need urgent attention too!

[paul2012]

Bargin

Lot of effort gone into this, are you keeping it or selling it when you've done?

Normally once I complete a project, it's sold on & I start a new one.

I have not decided if keeping or selling this one yet

[paul2012]

Not to mention the satisfaction of having created a one off van yourself, money can't buy that for most people!

Great project fascinating, keep it up.

Thanks, more updates on the way - Hopefully have new engine fitted in the next day or 2

Wiper arms need urgent attention too!

They do look abit worse for wear

[paul2012]

Fitted the 2007 engine bay loom today



Nest step fit ABS pump & pipes

[paul2012]

Typical according to Photobucket I've exceeded the 10GB bandwidth limit
All pics I have posted here on the forum are not Viewable until it resets in 12 days time

In the mean time I have a second account for pics to continue udating this thread.

for the second time

2007 engine bay loom fitted

[paul2012]

If you get gearbox from a Focus 1.8 TDCI from 2005 onwards

They are NOT a straight fit

Both rear & top gearbox mounts have been revised.

The connects rear mounting bracket will only box with only 2 bolts instead of 3 - Ford replaced the cast iron bracket with an aluminium one & changed the rubber mount
As for top mounting bracket the connect one also can only be bolted down with 2 bolts instead 3

This applies all Focus / C-max & Mondeo 1.8 TDCI gearboxes from 2005 onwards

This was something I found with the Mondeo 6sp box & working on a solution. I didn't expect the same on boxes from Focus 2005 onwards

You can use the complete rear mounting assembly from a Focus mk2, that fits no problem
It's the top mounting bracket that's the problem. The Focus one is approx 1.5" shorter that the connects

I will upload pics tomorrow showing the problem

[paul2012]

Well here the difference between gearbox mounts

This is the top mount - Connects one is on the left



& this is where one of the bolts holes don't line up



Notice the problem with rear box mount



This is the Focus one



You can use the complete Focus rear mount no problem (see below) I think the easiest solution is to use Focus top mount & fit a spacer with longer bolt

[phil drew]

as we used to say adapt and over come get it done

[liteace]

this is where one of the bolts holes don't line up



Notice the problem with rear box mount

Thats not a problem, just take that mount to a machine shop get them to mill that part flat and elongate the hole, look like there's enough alloy there to support it with the other 2 bolts, if not get them to alloy weld the underside and machine that as well

[phil drew]

fit the other one wiv a spacer and a longerer bolt cheaper simples

[paul2012]

Thats not a problem, just take that mount to a machine shop get them to mill that part flat and elongate the hole, look like there's enough alloy there to support it with the other 2 bolts, if not get them to alloy weld the underside and machine that as well

Wouldn't work

Arrow point to bolt hole, that connect mount has not covered it up completely



This is where the hole needs to be on mount (circled. Its right on the edge

[paul2012]

fit the other one wiv a spacer and a longerer bolt cheaper simples

That's what I'm thinking

or swap the internals over to the old box casing ?