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Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
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Massachusetts
I assume you removed the distributor gear to disassemble it? Did you have to use any sort of tool to remove or install it? I have a junkyard remote TFI distributor I recently acquired and that cam gear won't budge.

i actually didn’t pull the gear. I mostly focused on the top end just for the sake of cleaning/painting. The gear and shaft got a good cleaning but stayed intact for the most part. I didn’t really have much concern with regards to the bearings inside.

I mostly didn’t touch it due to horror stories I’ve heard with that gear. I already busted my alternator fiddling with it
 
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02 281 GT

Agreed...My wife has great Boobs
10 Year Member
Feb 3, 2009
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i actually didn’t pull the gear. I mostly focused on the top end just for the sake of cleaning/painting. The gear and shaft got a good cleaning but stayed intact for the most part. I didn’t really have much concern with regards to the bearings inside.

I mostly didn’t touch it due to horror stories I’ve heard with that gear. I already busted my alternator fiddling with it
Copy. I ask because it looks like it's impossible to change the pickup without complete disassembly.
 

Chythar

Recently finished repairing my rear
15 Year Member
Aug 26, 2004
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I've rebuilt a few 94-95 distributors. You are correct on removing the pickup. The cam gear either needs to come off with a press, or you can try setting the distributor upside-down in a vise, with the cam gear resting on top of the vise. Then tap on the distributor shaft with a brass hammer (to avoid damaging the shaft). The latter way is how I've done it. Don't forget to remove the pin in the cam gear, and mark which way the cam gear is on the distributor shaft. The pin isn't punched in the center of the shaft, so if you get the cam gear on the wrong way the pin won't go back in.
 

Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
36,384
12,293
224
Massachusetts
New alternator showed up. Brand new Bosch unit. Seems decent quality.

Came with a nice machined pulley. About 2” or so.
D9B5F378-B7CA-4598-9E09-427DD5B8E8B9.jpeg


When I had my underdrives I ran a 1 7/8” pulley like the gold one. Had zero charging issues. However I went back to stock crank and water pump pullies, so I need to do some math and make sure I don’t overspin the alternator.

I also think I need a black pulley. Guy on eBay sells them for $14/shipped in a few different sizes and finishes. That’s where I got the gold one. I’ll likely get a 2” black one

F1ED78AB-B19A-42C4-B581-EF6D7C21A928.jpeg


Started ordering parts to build my hydroboost hoses. Last hurdle so I can fill the PS pump up and get ready to crank the motor over.

oh yeah….distributor in too
 
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Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
36,384
12,293
224
Massachusetts
Ok did some napkin math.

With my old pulley setup i had an underdrive 4" crank pulley and a 1 7/8" alt pulley. I had excellent charge at idle with everything on with this setup and doing some math, i was spinning the alt 2.1 times for every rotation of the crank. I ran many, many years like this without issue

Now i'm back on the stock crank pulley, which is roughly 6". My small gold pulley is 1.9" so that will actually give me 3.2 turns of the alt per crank rotation. So i'm really overdriving the alt if i use that tiny pulley.

The silver pulley that came on the alt is 2.3" so if i use that, i'm looking at 2.6 turns per crank rev. This is still faster than my original setup but i just want a black pulley.

Motorcraft GP712 is a factory OEM 1994 pulley and measures around 2.1" in OD. Using this puts me around 2.76 turns. I think this will work fine and it was $10 on Amazon. A few more RPM at idle vs the previous setup, which will be fine for me as i sit in traffic with AC blasting and the e-fan on.
 
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WhiteCobra95

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May 2, 2006
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How did you cross reference the Motorcraft pullies? That's really good info, I didn't even know that they sold them separately.
 

Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
36,384
12,293
224
Massachusetts
How did you cross reference the Motorcraft pullies? That's really good info, I didn't even know that they sold them separately.

Rockauto listed it.

They don't have one for the fox 2G alt though. Only shows the GP712 being listed for the 130A alternator.
 

Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
36,384
12,293
224
Massachusetts
Got some AN fittings in. Testing my routing. I think I’ll need another 45* here instead of the 90*

FA2E6D57-C526-4673-BF09-09A72E2DDAD3.jpeg


I need to source some good quality 6AN high pressure hose. Any recommendations?
 

Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
36,384
12,293
224
Massachusetts
Also on the agenda, mounting this cleanly. This one is off an 4.6 SOHC but Ford had a few different styles with different mounting brackets. I might browse EBay and see if any seem to offer a better mounting solution. Obviously I’ll need to fab a bracket. This reservior is a bit yellowed, so I’ll likely buy a new one
95735D90-E2A1-465E-A0E6-AE42AAFAF764.jpeg


Here’s how it will plumb. Bigger port feeds the pump and connects to the port on the top of the PS pump.

small port gets connected to a Y- fitting and connects to the low pressure return off the hydroboost and off the steering rack (after the cooler. Small is the feed to the reservoir in other words

the pump is a factory pump with a rear housing off an car that had a remote mount reservior. I think turbo coupe or escort.

6AN conversion fitting already installed on pump. I’ll 90* of of this and run a line to the hydroboost feed port.
C3FF8801-89C2-4036-B024-9C3B57DB2486.jpeg
 
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Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
36,384
12,293
224
Massachusetts
Pulley showed up. Measures up at 2.1”. Everything black now. Time to find a belt that fits.

working on the hydroboost hoses. Parts slowing getting ordered once I figure out what I want

82AE6FA9-E727-43B2-A4DE-F3B53F8CF452.jpeg
1D931264-E139-46DF-8B98-705851E8B3D6.jpeg
7D32EE14-2A83-4025-8192-1578925F7C64.jpeg
 

Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
36,384
12,293
224
Massachusetts
So just to update. Had a minor surgical procedure earlier this week. Nothing was really wrong with me, but as a side effect of the procedure, I can no longer have any more kids. My wife is doing cartwheels.


Anyway, while i recover with bags of peas on my junk, i have some stuff on order to finish my hydroboost lines. I started with the two high-pressure lines. I did go with Vibrant Performance PTFE lines. I ordered the hose and then was brainstorming what fitting angles i needed for the various connections. Unfortunately some of the ones i decided to go with are not available until Sept. I'm sure i'd be fine with another brand of PTFE hose fitting, but i'd like to stay consistent, and i'd like to avoid mixing and matching different brand fittings. So i'll be waiting a bit. It's fine as i still need to plan my routing and make my plan for the low pressure side including the reservioir.


Problem #1. This little tube stub. Yeah there is some surface rust. It's been a HUMID summer here since it rains 2" every other day it seems. BTW, the black fittings shown are not what I will be running. Those got returned as they aren't for high pressure PTFE hose.

1630076062492.png



That little low pressure tube stub is a problem because on 03-04 Cobras, ford made that particular fitting Left Hand Thread. No idea why. The GT's and Mach's all have standard threading meaning there is a AN adapter fitting. Since mine is LH threaded, i am SOL. I could just slip the low pressure hose over the nipple and run a clamp, but I kinda want to run an AN fitting and use a 130* fitting. It's an appearance thing I admit.

I am looking to see if someone wants to part out a bad hydrobooster for this block only in RH thread, but my plan was to buy a 6AN bung, machine the bung and nipped so that I can press them together, and weld. A lot of work i know, but like i said, it;s an appearance thing. Since i have time, i might as well explore this option.

Another idea was to just machine the block and drill/tap it for a different size and install a banjo like the other fittings. My only hesitation here is that this low pressure fitting seems to also function as a restrictor since the internal port seems a bit on the small size. No idea if that's by design.

Once I get the hydroboost sorted, it's a day of small odds and ends and we can give it the first crank and see if it runs. After that, things should move quick. Put the rest of the AC stuff on, put the cooling system on. Wire up the fan and start putting the fenders and bumpers back on.

I do want to finish this project and be "done". I'm kinda getting tired of spending money on this project only because there are other hobbies of mine that have been put on the shelf for the last 2 years. I kinda want to get back into them now. I promised my kids we would put together a salt-water reef tank when the car is done. They have been very patient.
 
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Rdub6

So while I wait to figure out my rear end issues
Dec 29, 2017
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So just to update. Had a minor surgical procedure earlier this week. Nothing was really wrong with me, but as a side effect of the procedure, I can no longer have any more kids. My wife is doing cartwheels.


Anyway, while i recover with bags of peas on my junk, i have some stuff on order to finish my hydroboost lines. I started with the two high-pressure lines. I did go with Vibrant Performance PTFE lines. I ordered the hose and then was brainstorming what fitting angles i needed for the various connections. Unfortunately some of the ones i decided to go with are not available until Sept. I'm sure i'd be fine with another brand of PTFE hose fitting, but i'd like to stay consistent, and i'd like to avoid mixing and matching different brand fittings. So i'll be waiting a bit. It's fine as i still need to plan my routing and make my plan for the low pressure side including the reservioir.


Problem #1. This little tube stub. Yeah there is some surface rust. It's been a HUMID summer here since it rains 2" every other day it seems. BTW, the black fittings shown are not what I will be running. Those got returned as they aren't for high pressure PTFE hose.

1630076062492.png



That little low pressure tube stub is a problem because on 03-04 Cobras, ford made that particular fitting Left Hand Thread. No idea why. The GT's and Mach's all have standard threading meaning there is a AN adapter fitting. Since mine is LH threaded, i am SOL. I could just slip the low pressure hose over the nipple and run a clamp, but I kinda want to run an AN fitting and use a 130* fitting. It's an appearance thing I admit.

I am looking to see if someone wants to part out a bad hydrobooster for this block only in RH thread, but my plan was to buy a 6AN bung, machine the bung and nipped so that I can press them together, and weld. A lot of work i know, but like i said, it;s an appearance thing. Since i have time, i might as well explore this option.

Another idea was to just machine the block and drill/tap it for a different size and install a banjo like the other fittings. My only hesitation here is that this low pressure fitting seems to also function as a restrictor since the internal port seems a bit on the small size. No idea if that's by design.

Once I get the hydroboost sorted, it's a day of small odds and ends and we can give it the first crank and see if it runs. After that, things should move quick. Put the rest of the AC stuff on, put the cooling system on. Wire up the fan and start putting the fenders and bumpers back on.

I do want to finish this project and be "done". I'm kinda getting tired of spending money on this project only because there are other hobbies of mine that have been put on the shelf for the last 2 years. I kinda want to get back into them now. I promised my kids we would put together a salt-water reef tank when the car is done. They have been very patient.
Dude!!! Get that car finished and get the fish tank going. They’re at the age where the tank will be perfect for them. Then when they get older, ease them back into the cars!
Ive had had some pretty serious freshwater tanks but haven’t crossed over to the salt, but it’s definitely on the list of “gotta do that” hobbies!
 
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Mustang5L5

Put lubricant all over the balls
Mod Dude
Feb 18, 2001
36,384
12,293
224
Massachusetts
Ok some parts showed up. Started assembling my PTFE hose and hose ends.

line of the PS pump done.
36E15C13-1036-42C3-BFB0-511BA11A353C.jpeg


Of course, my 45* ptfe ends are arriving this week due to backorder. The line off the pump will connect to the larger banjo closest to the engine with a 45* connector.
685F62A8-C338-477A-970B-6A39CDB52C9B.jpeg


the other banjo will connect to the power steering rack with two 45* on each side. That will take care of the high pressure side of the system. Basically the hydroboost pump is plumbed in series with the steering rack. Pump, to booster, to rack. Then the low pressure outputs from hydroboost and rack flow back to the reservior
 
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