Gen 4 Transaxle Conversion 2D to S4/S5

[Old Skool]

Need some guidance / Pictures for changing out a 2d to a S4/S5 Transaxle.   I reached to to @onanysunday and asked him for pictures of his conversion that were lost in the change over.   He suggested that I ask on here so that he could re-share them with everyone if others are in need.  

 

[onanysunday]

Will do this evening when I'm back at my desktop with all those photos.

 

[J Alper]

Doing one right now,  

Couple of things,  the end of the hokey stick is pretty much where the S4 will end up,  the cars i have done, i had to cut out the torsion tube, and brace under and above it, 

Depending on the car, the one doing now i cut out all the trans brackets and used the motor mounts to reference the trans,  did not want to move the motor due to wiring water lines ect. some will modify the trans mounts and move the motor,  really up to you,  

The other part of the work is removing all the interior so you can mount the new shifter, this can be a ton of work also.  

Will also try to take some pics,  but slammed till prez day, 

 

[Duffordraw]

My Gen 4 had this conversion done prior to me buying it. They did not cut the torsion tube - which left the trans and motor too far back in the car and I could not keep the front down at all- totally changed the car's handling for the worse- doesn't turn very well well when the front tires are off the ground.  

I had to have it all redone, torsion tube cut and everything moved to where funco puts it when they build them. I had Arvizu Fab in Tucson do the work, did a great job and I love how it turned out. 

 

[URCLEVER]

My buddy just did S4 to s5d and it was expensive. Changing of tubes angle of engine and plumbing got changed, exhaust, trans was 19k I think. I would call grant he can give you the details.

 

[onanysunday]

So here is how I did mine. First I made these jigs which I should still have if someone wanted to use them. I did use the original 2d mounts on this project. I thought someone had said you should remove them and redo but it worked fine for me. It wasn;t exact but very close when the s4 went back in. I went from 930s to 934s and my angles were fine without any change if I IIRC.  If you look at the pics you can see a small gap at the top and where the difference was. 

 

[onanysunday]

Pics of the s4 mounted in the stock location of the 2d mounts. And crossover tube removed. On my car I had to cut into the sump for the tank as well 

 

[onanysunday]

New crossover tube and steel plate welded in. 

 

[onanysunday]

Cross tubes and fist pic shows a fixture I made to use a motorcycle jack to roll the trans into place.  If I did another one I would not bring the bars quite as close to the trans. Very tight and hard to get to everything.  You can see in the last pic and one other pic where I had to notch the tubes each side for clearance.

 

[onanysunday]

 

[onanysunday]

 

[onanysunday]

Also on my car I did the mega boxing of the arms. At a later time I added microstubs to these arms and wish I would have stayed with centerboard hubs. Just because the bearing assemblies don't last when you beat on your car. I will be buying the Kartek units with rebuildable bearings thought.  My car is like a tank in the back now. Much more than shown here. And of course a redesign on the pivot for the airbag. So much trouble with this over the years and finally fixed the issues. All Funcos should have this upgrade. 

 

[onanysunday]

 

[onanysunday]

In the last pic of the last post you can get a good view of the gusset added to each side of each trailing arm pivot mount. And the bigger monster bolt vs stock. Couple of pics including this one you can see steel wrapped around the arm where the uniball goes. 

 

[onanysunday]

I remember that fuel line was very tight so I cut off the boss for the gear indicator.  You can see in pics in previous post. 

 

[onanysunday]

2d reverse vs s4. I also did the treatment on the gears when this was built. Don't remember what it was called.

 

[onanysunday]

I went with the Funco shifter and it is awesome. Worth every penny. Long handle with lots of leverage. I will say the turning brake is further away and you have to use more shoulder to work it. I left it open on my car with no console. I like to see mechanical things so no problem for me. 

 

[onanysunday]

Looking back at my first post reminds me I did not go to 934s right away. That was an adapter from 934 to 930. What a PITA that turned out to be.  It was horrible because later on I couldn't get the tapered bolts out. Turned into a nightmare. So much work in those damn things. Sheesh I have this car sitting at the shop and will be missing the whole season. chit.  

 

[onanysunday]

Been a long time since I did this but IIRC the motor mounts had to be redone since the motor has to go up in the air. Same with the water lines.