96 Talon to 97 GSX swap

[hzagadinow]

@ some of your eariler posts...woman are crazy, my ole lady hates my car so much that she curses it daily but I took his pampered ass out of the new Bimmer and Benz and made her drive my un-tunned 96' rusted DSM with a busted up driver's side door panel, a light weight flywheel and no AC to work for a few weeks...she hates my 2G even more but cringes at the possibility of me not buying her what she wants.

 

[bmoha7321]

 

[bmoha7321]

Blown balljoint on steering knuckle. Gotta order one.

 

[bmoha7321]

 

[bmoha7321]

Mangled sway bar link on this side. I'm open to any suggestions for good inexpensive replacement for it

 

[bmoha7321]

GSX is now on the ground on it's own tires off the jackstands!

 

[bmoha7321]

I'm not sure what to do. I had a problem when I was removing the front subframe that the one stud just spun and spun. I'm running into the same problem now that I've reinstalled it. I made a couple exploratory cuts with a dremel tool and it didn't work at all. I'd have to cut thru another layer of sheetmetal to get to anything. And I'm not willing to do that. I will get the removed and cut pieces welded back in but I don't want to do anymore cutting... I don't want to sacrifice the structural integrity. I'm kinda stumped as how to fix it. I thought there would be a large 4 side nut on the top of the stud bolt.

 

[bmoha7321]

also I misplaced a brakeline banjo bolt and my non cruise control throttle cable! Argh!

 

[bmoha7321]

This is how it's sitting now. ACT warrantied the clutch and is sending me a new one.
I just ordered a brake banjo bolt from JNZ Tuning and will probably have to order a non cruise control throttle cable as well

 

[Boosted DSM 32]

Wow thats so disrespectful that she would do that! Thats one reason you dont see as many of these monsters still on the street that are in good shape..

 

[bmoha7321]

Just ordered OEM TOB and non cruise control throttle cable. ACT sent a replacement TOB with the warrantied clutch replacement. I tossed it in the trash. Just don't trust it at all. Lost my non cruise control throttle cable during the shell swap. Had to order a replacement.
Still trying to track down the fittings for plug off the power steering rack.
Still deciding if I'm going to try to do the timing belt before dropping the motor and tranny back in or not. I really want to but I only have 7 days left until I need to get out of the storage I have the car in. Just too expensive!

 

[bmoha7321]

Ordered all the parts for timing belt replacement and BSE. New water pump, oil pump gasket kit, valve cover gasket, oil pan gasket and a set of Jay's racing timing belt tools.

 

[bmoha7321]

Balance shaft delete done! Kind of a pita! Water pump replaced which was a good thing as the original one looked like it had been hitting itself and scoring the wall. Replaced the oil pan gasket, all front case seals and gaskets and oil pump gaskets. Everything went pretty smoothly. I had a helper who has done about 40 timing belts on DSMs so it made it much much easier. Couldn't have asked for better weather or a better helper. Going to put tranny back on motor and drop into GSX shell Tuesday.

 

[bmoha7321]

 

[bmoha7321]

I have this handful of plugs leftover... This is on the small lead from the main wiring harness that runs along the firewall from passenger side to driver's side. not sure what they all are.

 

[bmoha7321]

 

[bmoha7321]

motor and tranny in. I cleaned up the motor quite a bit. Not show quality but I knocked an amazing amount of crud and off the motor and trans.

 

[bmoha7321]

 

[bmoha7321]

 

[bmoha7321]

 

[bmoha7321]

this is the progress so far this evening. i worked for 8 hours on my day off. Kinda tuckered out. I was about 15 minutes away from being able to try to start it and... I seem to have lost the negative battery terminal. Not sure where it went. I know I had it and now it's gone. Not quite sure what it connected to what exactly as I've never really paid attention to it except to tie it down to the battery. So I'll have to fab up and new one tomorow after work.
I am bringing all my ic pipes, the intercooler and the intake to work to blow the dust out of them. All the painting work left a ton of dust inside and outside of all those parts even tho they were covered and and the other end of the space.
I still have quite a few connectors that don't seem to connect to anything currently. I think the 97 GSX wiring harness has quite a few more options than my 96 talon tsi awd wiring harness did. This one has a sensor to activate an underhood light. The Talon never had that.
anybody know what that part is I'm holding in my hand in the last pic? I don't recognize it. Don't know what it is or where it goes.
Also the 97 GSX wiring harness has two (?) plugs for the lights? The is only one plug on the underside of the lights

 

[gieri002]

That is the injector resister box, it bolts onto the firewall.

 

[bmoha7321]

Hmmm damn. That makes it sound important

 

[bmoha7321]

I broke the mid timing belt cover while doing the timing belt. Not going to run the vented cf hood until I have full timing belt covers on it. Going to get one of those Zak Lee clear covers if they're still being sold.

 

[delta448]

Sorry I'm just now making my way in here to check your blog out. Looks like you're moving right along though. Nice work so far!