Hello there...

Thought id post this here, even before ive "started" my project.
I am just starting to thinker around with an idea about what to do with my good old Mondeo.
Ive started a few "smaller projects" on the car before,
but they have all died of old age before i have finished them.
(zetec turboconversion, and a few other smaller things)

The car have been out for sale about a year now, and i even offered to give the car away for a kinderegg
http://www.ferrero-kinder.de/flash.htm
(cheap chocolate)
Still no luck...

I was actually planning of making a Audi trackday car, but figured i could rather use the good old Mondeo i already had in the garage....
Still, i want to keep the license plates on my car, and Norwegian rules for modifying cars, are hard to meet.
There are no real guidelines, and nothing is actually allowed.
We dont have Single Vehicle Approval (SVA)
But im gonna try to get this through...

The idea is atm, is to RWD my Mondeo with a 2.5 V6 Duratec engine.
This is because the engine is kinda easy to get hold of, tune, and the weight.
And if im correct, ST200 brakes are standard on the 4x4.
(give me a slap if im wrong)
Must say that im dreaming of a turbo V6, but if i ever gonna get this approved by Norwegian authorities,
i have to settle to around 220 BHP.

Remember the main idea is to get this street legal and approved.
And NO, im not gonna sell my house to found this,
so its on a mild budget, and a loong time scheme.
Still a mild tuning of the V6 aint gonna cost a arm and a leg if my info is correct.

So now i need some help with what kind of gearbox i can use on the V6, to get my weights and data correct,
for my application to modify my car.
What kind of rear diff i can use, and ive got to sort out steering and alot else... so tips and tricks are welcome!!!

I need technical data on both the mondeo 4x4 and the ST200/ST220
i need weight on the gearboxes on all cars, axel loads, engine weights, and total car weighs

some data on the car?
1996 Ford Mondeo 2.0 16V 4x4 CLX. /BAP4
First registered 29.11.1995
The car is plain, with no extras, except electric front window defroster, and AC.

And yes.. pictures? well lets see what ive got on this mondy...
Some old and ugly pictures... not a newly polished car ;P






Having a "few" Mp3 i got tired of burning CDs, so i did a early carputer installation.
Music videos where kinda fun, the supermos pornedits where not safe to play in traffic hahaha




Zetec turboconversion done, never installed
Due to the (said to be) weak transferbox on the 4x4, and my lazyness
Bought moust of the bits from ppl in this forum.. thanx guys.


Ive just started to clean my garage, to start stripping this car.
in the meanwhile, tips and tricks are welcome

In the end, the car is gonna look kinda ordinary, with new paint, perhaps morettes, and rs bodykit...but no hurry.. lots to sort out before finishing details

 

Interesting idea! No idea how you'll make it all work without spending a fortune though, as you'll need to be very creative with the drivetrain!

For the engine stick with a lightly modified ST200 lump for 200bhp. Trying to chase those 20 extra will cost you way more than you'd expect.

 

The mondeo is 4x4 atm, so ive got the tunnel for drivetrain.
Think i have to change the rear diff, for a stronger one, and if you are talking about the driveshaft itself, getting the correct length should not be what kills this project.
The 2.5 engine is kinda short, so it should fit. Trouble is finding what gearbox i can use, and getting that to fit, since mondeo has a transverse engine... there isnt much room "back in the car" for a gearbox. but that should not be to big a issue..
Think steering might be the biggest trouble atm... but first i gotta sort out gearbox,and see what room ive got...
I also have a good supply of sierra, scorpio parts from a scrappy

 

your gearbox at the moment is transverse so you have only got a prop shaft running down the transmission tunnel, if you want to fit the engine in longditudinally then your gonna need a much bigger tunnel

 

Think i have addressed this problem, but my English is not too good..

I might have to cut the floor from a Sierra or Scorpio to get this sorted.. i know..
*edit* got a tip to look at Jaguar for gearbox.. RWD, Mondeo based, and similar engine? hmm .....

 

as said you may have a tunnel, but it is only for a prop shaft and no use for a gearbox. as for making it rwd in the current tranverese setup is near impossible or just stupidly expensive to try to make transfer boxes, diffs ect strong enough for the rwd.
the only possible option may be evo running gear
that leaves you with turning the engine lonitudinally which is another tough job given the duatec v6s fwd roots and the mondeos fwd subframe which is in the way of everything.
the way around this would be fitting a sierra subframe and suspension and a custom sump on the v6. then you will have to cut a fabricate a gearbox tunnel to use either an mt75 rwd box or possibly a t5 with custom bellhosing. then finally you will have to deal with a rear diff and axel setup that i am fairly sure could not handle 200hp(maybe it can but never seen it done)
all this leads back to why not use a sierra in the first place and you would never even need to get an angle grinder out.
you would want to really like mondeos to attempt this job

 

Seems like we all agree...
I have no room for a gearbox. I know i have to fabricate that.
Thats why i need to figure out what gearbox works with RWD V6.
Then i need to make room for that configuration....

And i never said this is gonna be easy or done in a few days...

 

sounds like a good project and one that hasn't been done in ages! Personally I would rip it all out and start again. Ditch the 4x4 as it's known to be weak. Either fabricate a four linked english set up. Or cut out the back and weld in sierra floorpan, then your diff and suspension will all bolt straight on. With regards to a RWD box for the ST V6, I'm sure there will be one that is either a direct bolt on, or one that just requires a conversion plate. Then fabricate your tunnel, and fabricate your engine mounts, a Mk2 subframe will probably be the best bet as you can work from there to mount the engine. And the rest is all fine finishing.

I have used subaru running gear on a conversion for a MK3 fiesta, it pretty much bolted straight up with a few fabricated mounting brackets. Also BMW's rear end is worth looking at, go down the scrap yard with your tape measure and take a look at a 90's 3 series rear end. The whole lot is suspended from 3 bolts to the floor pan and then the shocks to the struts, it's very simply designed and a lot of the bmw's diffs have LSD's etc, might be worth looking at.

Other than that, if your dead set on keeping the engine as it is, look into audi's quattro gearboxes, I know at least 3 people using these at the moment, and it was a case of fabricating a conversion plate or re drilling the bolt pattern to allow the gearbox to fit onto the ford engine properly. I think a few A3's run a 3.2 V6 so that might work size wise and streagth wise too.

 

Thanx for one positive post
Ive got "unlimited" supplies of Sierra and Scorpio parts, so ill try to work with that first...
Gonna be alot of trials and errors

but it is gonna be fun...

 

To be honest mate, you'll find on forums there's those that talk a lot, and those that do it. I remember when the zetec first came out. Hundreds of people were barking on about how it couldn't be turbo charged properly, what are we up to now...........6-700 BHP. Forums can be like that, a load of people just going off of what someone else once said.

Anyone remember ben birch barking on about and laughing in performance ford about how you couldn't fit a dump valve to a super charged installation, he left the magazine not long after that, wonder why?

If you think you can do it, and really stick to it, you can do anything with cars, it's so simple sometimes it's a wonder why people get so worried about things.

Last year we put 15psi through a carb on a 120k 1.1 fiesta, and it's still going strong today, no internal mods, nothing, just plumbed it up with some knowlege from a book, and bam, jobs a good un. "they" said it couldn't be done, it would cost a fortune and it would blow up!! second hand parts that cost less than a second hand zetec and a combination of charge and intercooling with a particular fuel regulator from the states, and it recorded 170BHP on the rollers. No tears no blown engine, in fact everything "they" said would happen, didn't. So where people get thier information from is beyond me.

If you have a floor pan from a rear drive ford, your 50% of the way there mate, building a jig is easy, welding the floor in is easy, it just takes blumin ages and it's a methodical job, it's only scary if you listen to what some people say about conversions in general.

I wish you the very best of luck with the mondeo mate. The second you cut the floor pan and post a picture you watch how positive the posts get, because your doing something people wouldn't even think about doing to a car, never mind the practicality of it.

You get it chopped out after some measuring, and you'll laugh at how easy it all goes together, I bet you'll be getting paid to do it for people after you've figured it out, it's all common sense with the fabric of a car.

Engine managment on the other hand is a very dark art to me ha ha, so I can't comment on that aspect of modification.

I'm not saying everyone is miss informed on this or any other forum, but the majority of times I think it's too easy to put people off making what they can see in thier heads as working coming to fruition. If we all listened to people who only say negatives about modification, we wouldn't be where we are now.

Just do it, if it goes wrong, post on here for help, simples.

 

well, have spent some time cleaning up my garage lately.
(it still looks like a mess)
Today i removed the first bits and bolts on my car. So i can finaly say i have started.
Still havent found out what kind of engine im gonna put in...
Going to be either 2.5V6 or 5Vturbo.


Did get moust of the interior out today.



Stuck bolts?? heh..dont think ive ever removed the rear ones.


Some rust..old fords never die...they rust, or go faster


My girlfriend doing her thing....


sorry about crappy cellphonepics...

 

This will be an interesting project.

 

Hi Mondeo4x4! In my country (Hungary) there was a rally escort Mk3 with a Zetec turbo engine, uprated mondeo/rs2000 transmission and a custom made transfer box with Audi torsen diff internals - the complete car for sale for about 63.000 NOK. I saw the photos of the build, everything seemed bulletproof. CNC machined, thickwall transferbox case, etc. I seriously considered to buy this car, and put the transmission into a road legal 4x4 mondeo. We have strict rules for modified cars also, nearly nothing is allowed. Considering you have a zetec 4x4, replacing this with a zetec turbo + stronger 4x4 would be the most hassle free way, maybe. If you need more info, contact me, and I'll forward the builders contact details. I'm sure, the price could be discussed also, in case of serious interest. I have no relation with the company.

 

I think i have seen that car> I dont know about its performance ,but it looks ridiculous! i think its a 4 door too!

I will try to find the pics.

 

Here's the sort of size tunnel you need for an MT75 box..

 

i like the look of this!...have you considered the 24v cosworth v6? that way you could use either an mt75, t5 or type 9 box no problem at all and if you have access to scorpio's then parts shouldnt be a problem

 

What about Jaguar X type running gear ?

Transverse engine, 2.5 or 3 litre V6 and 4WD if I remember correctly.


Mark

 

VTS FREE -Is it this one?

 

That's it... errmm....let's say the body isn't the nicest part of this car...

 

Havent done much lately.
Have to spend some time with my daughter and my girlfriend too
Some things i have done:
Have bought 2x 2.5 V6 engines, one complete with management.
Have bought some parts i need to replace.. got some rust below the doors.
(dont know the word for it )
Did have a quick look at a Sierra XR4X4 today, but raining like mad and 4degrees, ill take a better look at donorcars later...
But the gearbox-tunnel didnt look that much bigger on the Sierra

Thanx..

Have "recently" divorced, and that was kinda expensive ;P
And the fun is to build but thanx for the tip.
Im also going RWD, for more fun at trackdays...

Thanx.. still is not shure what gearbox i will mate with the engine.
Think to just weld in a gearboxtunnel from a Sierra/Scorpio,
with gearbox mounts for MT75 is perhaps the easiest to do.
But im actually also looking at BMW gearbox since they can handle abuse, and are cheap/easy to get hold of.

If i get hold of a good T5, that might be the best, but those costs around £900 and upwards here.

Depending on what gearbox i choose, i still have to make an adaptorplate between engine and gearbox.

Thanx
I have noticed the BOB engine, and those are kinda cheap here..
(£900 for a good working engine)
Still i have not considered that engine for my car. I have a faint hope to get this car road legal, and since we dont have SVA here,
i need to get the car as "original" as possible.
Mondeo is available with 2.5, and not 2.9. And if i dont get this approved, 1 or 2 turbos should get me satisfactory power to play with...
I have no intention to try to win the "power race",
and i dont have the founds to do that either
Need like 600+ BHP to be in that league
or what about a 1700BPH Granada :P street legal....
http://www.youtube.com/watch?v=Q0WaS...rom=PL&index=7
And another one is being build where they hope to reach 2010BHP..

Ive looked at it, but that was an earlier stage, before i decided to go RWD

 

Been working alot of late nites lately,
and this is week i have my daughter, so havent been doing too much with the car.
Have just started to look at the 2.5 engine.
Gonna service it before i do too much more with it...
Its good and dry, but have got quite alot of milage on it.
Im not too familiar with the 2.5, so tips and hints, are welcome.
(any good tips for service kit?) And what i should do?
Ive heard the waterpump is a weakspot, so im not shure if im gonna use an external pump... time will show.
The other 2.5 im getting in 3weeks time, has low milage.
Have not decided what im gonna do with the two engines.
might be handy to have one spare, and i have an idea of turbocharging one of these also

Have sold the old engine, and got an offer for the transferbox, but i dont know if im gonna sell it.

Still ive got the fueltank and small pcs left to remove from the car...

Now here is a question for you.
Im gonna replace the panels under the doors (dont know the word for it)
But the part has been dented by carjacks and got some rust on it..
(guess you know what part now)
and i should make myself some sort of jig, before i start cutting the gearbox tunnel?
(dont want the car to be completely wrapped when i start cutting the gearbox tunnel)

 

Vauxhall ran a development of the 4wd cavaliers as RWD for touring cars, they did it simply by locking up the transfer box and removing the front driveshafts essentially.

 

why didnt you just zetec-turbo or focus RS it instead of going for the v6 which has limited and expensive tuning capabilities?

also the 4x4 transfer box on the mondeo isnt to be confused with the one on the escort Gti (half the size of the mondeo one) which shits itself at 250bhp.

and why chop all the floor out to fit sierra bits when you could just get the 4x4 gearbox and transfer box shot peened

 

Maybe a daft question but without the front drive shafts in will the hubs not fall apart?

 

not if you fit the front wheel drive front hubs

 

Ah I see. Cheers

 

1) norway is one of the hardest contries to get modifications approved.
we dont have SVA or, other to help us when modifying cars, so its all ending up with what the car have been approved with, from factory. (is type designation right word here?)
Different rules have been applied during the years, and the my mondeo is "so new" so ive gotta get passed ALOT of rules and regulations.
This includes, ive gotta document what the chassie can handle of power, and moust any thinkable data.....
The easy way, is to take the car to TÜV and see if they can approve the car, but thats too expencive for me....
AND as said before, i want my car road legal.

so my first idea was to get the V6 and Sierra drivetrain in the car for some RWD fun...
But it was no chance in _HE*L to get that approved. If the mondeo had been delivered with 4x4 and a bigger engine, i could have upgraded to match that model, but 2.0L was the biggest engine on the Mondeo.

Been some back and forth with the authorities lately, and therefore no updates...
No need to post everytime ive unscrewed a bolt or a bit

But for an update, i have actually managed to get green light to install a 150HP turbocharged engine in my mondeo, so i have gotten some progress there.
Not ALOT of power to brag about, but as i know, it would be the first legal turbocharged Mondeo4x4 in Norway... There is a 400BHP 4x4 running around near by, but i know he have to work hard to get that legal....

 

some good idea's