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With the mock-up complete, it was time to chop up the actual car
Stripped, braced, floors and front frame cut out
I really want to convert the S10 drag link to rack and pinion. To accomplish that, I had to chop up the S10 frame extensively
Taking out the idler arm "hump" and top ridge on the crossmember
That all clears, how about low mount AC while I'm cutting
Time to box it all back in and cap any remaining big holes
This was the 3rd round of trimming stuff off this little frame stub. Still pulled about 40lbs off. A decent chunk of that had to go back on, but still substantial
I threw the frt suspension back on for a mockup. Front fits as good as original
Beginning the front frame splice
Done
I threw the mock-up back in to check how everything fits. I'll need to cut the rest of the tunnel out as it has hard contact with the bellhousing. Then to tie the SFCs to the rocker panels
The oil pan came back, so I did a full mock-up. Began planning the steering rack mounts. I'm happy to report the front diff is so much easier to R&R than trailblazers
Lots going on in that little space
Dropped down to ride height, the CV's are still within safe range (24*)
Tons of ground clearance, actually much better than any 3rd/4th gen
Far enough along that I can order the front driveshaft and start building the floor
I slid the mustang 8.8 under the car. Only mods are fbody brackets welded to the axle tubes. I have a 31sp yukon diff, 4.10's and new axles to go in at a later date. Instead of a traditional side mounted torque arm from a Hiltsy kit, this is a maximum motorsports TA for 70's-04 mustangs. Perfect length to miss the t-case
The goal was to use a heavy duty semi-common 6 speed manual in order to get experience for future manual 4WD/AWD builds. T56 conversions are well documented. I haven't seen one done with the easier to source T56 magnum and it's oddball 31sp output shaft
If I were to use an automatic, it'd be a common 4L80E
Don't get me wrong, I love the work you're doing with the ZF autos, but they just don't fit the bill on this build
The goal was to use a heavy duty semi-common 6 speed manual in order to get experience for future manual 4WD/AWD builds. T56 conversions are well documented. I haven't seen one done with the easier to source T56 magnum and it's oddball 31sp output shaft
If I were to use an automatic, it'd be a common 4L80E
Don't get me wrong, I love the work you're doing with the ZF autos, but they just don't fit the bill on this build
Fair enough. There is also some mystery about the transfer case controls from the BMWs.
Word has it that the Dodge truck transfer cases use an external controller, which might be easier to adapt.
I went through 6 transfer cases before going forward with the hybrid BW 4404/4472/NP241
Center differential
Viscous coupler
Non-computer controlled
Heavy duty
The biggest hangup was the 31spline input shaft. That's unique to ford and I couldn't find a machine shop willing to broach an existing shaft to match
Cracking open the BMW t-case will tell alot about how it functions and how to control it. Most modern AWD cars use two systems:
An open differential and an active ABS system to keep the wheels turning the same speed
A permanent 2WD output and clutch operated 4WD/AWD. Computer controls for the clutch electro magnet
I'd be shocked if it had a coupler or torsen diff. Bean counters hate the cost of mass producing those
I was going to mention the NP149, but I'm glad I didn't after going over there and reading that whole thread. Whole project is amazing...but that t-case setup is next level...
06-21-2024, 10:20 PM
91 Trans Am AWD LSA/T56 Magnum build 
