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  • Member For: 4y 2m 20d

Hey guys, hope this can be of help to someone out there. 5 months ago my housemates 09 n/a xr6 5 speed started slipping gears, as most, if not all of you who have had the displeasure of owning one of these time bombs know, the day of the glittery oil pan had come and his 5 speed sh*tbox had come to an end. Myself being an apprentice at the local ford service centre saw this as an opportunity to learn what's involved with a 6 speed conversion.

To begin with I already knew on the 6 speed the TCM (trans control module) was built into the box, therefore didn't need any extra plug into the ECU whereas on the 5 speed it didn't have the TCM built in, so it did need the extra plug.

We bought a 2012 mk2 6 speed with the tailshaft (slightly shorter than the 5 speed), shift linkage on the side of the box, engine wiring loom, trans cooler and ecu from a wreckers, we fitted all the parts and found that that the holes to bolt the flex plate (also known as flywheel on manual) to the torque converter were 20mm inwards, after a quick ebay search we found the 4 speed and 6 speed have the same flex plate whereas the 5 speed is different, after fixing that and getting it all together the car wouldn't start, we took it to my work and attempted to program it, we had a few codes but the one that stuck out was for the IC (instrument cluster), which was for incorrect vehicle speed input, after that we were stumped, we then searched around everywhere and couldn't find any threads on a conversion being done, we rang a shop in baccus marsh (GW auto care 0455 781 227) who specialise in falcons and fords, who were the only people that genuinely wanted to help us and were very friendly, they told us we need to change the loom that goes from the bottom of the engine bay fuse panel (we changed whole fuse panel) to the back of the interior fuse panel and the loom the plugs into the top front of the engine bay fuse panel and runs around the front of the car all the way to the inside of the passenger footwell (need to take front bumper and both front inner gaurds to access (which is not easy to maneuver but is possible, goodluck), the car finally started, it drives but won't come out of 1st, when shifting to sports, the D symbol on the dash doesn't change to S and doesn't change to 1 or 2 when you shift up or down when at a stop, hope this has helped someone and if anyone can help us get her shifting it would be much appreciated, this is my first post and hopefully not my last, please be kind I'm not an expert so please correct me if I've said anything wrong and please be free to ask questions.

Cheers from the half pissed Thiccc_g6e

P.s long live the BARRA!

Edited by Thiccc_g6e
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  • less WHY; more WOT
  • Site Developer
  • Member For: 15y 11m 19d
  • Gender: Male
  • Location: Melbourne

:Welcome2FordXR6t:

 

solid first post.

 

The 5 speed to 6 speed, as you found it, isn't a common changeover as it's cheaper and easier for an N/A to just get a replacement 5spd.

Good job on the fault finding the way you did and I'm sure with a ZF TCM tune it'll fix the "not shifting" problem.

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  • Member For: 8y 5m 21d
  • Gender: Male
  • Location: Mildura

Well done mate, not many people have attempted to do this.

I had an issue with my old 6 speed that when I pulled the engine out and put it back, I didn't have the linkage cable mounted or adjust properly.

When I drove off, it wouldn't shift gears and got stuck in 3rd. Not sure if this helps but it might.

Also there's a loom that plugs into the zf shifter that sends signals back and forth. Did you change this one?

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  • Member For: 4y 2m 20d

Thanks for the help and compliments, yes we did change the loom as well as the shifter itself, sorry I forgot to mention, we've got PCMtech and the ford IDS so hopefully that helps but I will keep you all updated, cheers 

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