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Old 05-09-2016, 09:05 AM   #101
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Re: sutyak's turbo 2004 Mach 1 build thread

Nice, shame they aren't just bolt in..are they like a universal seat or Mustang specific??
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Old 05-09-2016, 09:14 AM   #102
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Re: sutyak's turbo 2004 Mach 1 build thread

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Nice, shame they aren't just bolt in..are they like a universal seat or Mustang specific??
They are Mustang specific brackets from Corbeau. Yeah you'd think they would fit perfectly.
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Old 05-09-2016, 09:15 AM   #103
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Re: sutyak's turbo 2004 Mach 1 build thread

I bet your wallet is saying the same thing
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2003 DSG Mach 1-03 Cobra Term/T56 swap:
2.3L Whipple,3.37 Upper,4 lb.lower, ID 1000 injectors,LCD cooling mod,Billetflow idlers,200A Alt,oil cooler delete with MMR adapter plate,MM oil filter kit,FrozenBoost Heat Exchanger Flowtech L.T., Maganaflow O/R X with Magnapacks, FRRP D.S.,T-56 with 26 spline input shaft and anti venom mod with reverse lockout box, FR steel flywheel,Spec Stage 3+,Moser 31 spline axles,FR 3.73 gear
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Old 05-09-2016, 09:24 AM   #104
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Re: sutyak's turbo 2004 Mach 1 build thread

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I bet your wallet is saying the same thing
My wallet is too busy crying over the TR3650 rebuild cost.
Oh well, it should be nearly bulletproof (and track legal) by the time I'm done with it.
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Old 05-11-2016, 09:03 AM   #105
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Re: sutyak's turbo 2004 Mach 1 build thread

Made some progress on the car last night. I painted the wiper arms, hooked up the wideband to the XCal3 firewire cable, and figured out why neither power port works.
I had never needed to remove the wiper arms from my last Mach 1, so I had to do some googling to figure that out. The arm has to be raised completely before it can be pulled off. Once raised, pull out the small pin (it doesn't come out completely) and it will wiggle right off.

After much wire tracing and voltage checking, it turns out the power ports simply weren't connected! There is a connector to the left of the shifter that was not plugged in. The other side of the connector was nowhere in sight, so forgetting everything I knew about the last Mach 1 I owned over 10 years ago I assumed it was diagnostics. That is until I actually traced the wires. It wasn't until after I started removing the center console that I could see the other end of that connector. Whomever installed the center console last tucked the connector back where it could not be seen.

I also purchased an SCT license for the car so I can tweak on the tune. It took a couple tries updating the Advantage software but it finally showed up. I hope to do some data logging in the next couple of days, but the rain is not helping.

Before paint


After


Power port connector. The male end was tucked under the console.


XCal3 wiring diagram. Verified output voltage is good, but have not done any logging yet.
I was really hoping the AEM boost controller had an output wire, but no luck. I may add a MAP sensor just for data logging in the future. I like being able to log the boost pressure.


Firewire cable on passenger side
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Old 05-11-2016, 12:41 PM   #106
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Re: sutyak's turbo 2004 Mach 1 build thread

nice update, the wipers can be a challenge if you have never removed em, but really easy, your not the first to need to know this.
good luck with the rest of the install

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Old 05-12-2016, 09:22 AM   #107
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Re: sutyak's turbo 2004 Mach 1 build thread

Exciting evening is one way to put it.
I went to get everything set up to start data logging and adjusting my tune with the Pro Racer Package, but the Livelink II application told me my X3 firmware was too old to log with. So I downloaded the SCT updater application and ran it. It warned me to flash my car back to stock before proceeding, so I regrettably did.

Ran the update. Update failed. Bricked my X3. Car has unusable stock tune.

I'll be calling SCT first thing today. Already sent a support email last night.

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Last edited by sutyak; 05-12-2016 at 09:38 AM.
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Old 05-12-2016, 11:41 AM   #108
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Re: sutyak's turbo 2004 Mach 1 build thread

Called SCT. They remoted into my laptop and the X3 is currently updating. The tech had 2 files: a LFU file, which is basically a format file to wipe the X3 and prep it for a big update, and an LWU file which is the firmware. Neither are published from SCT.
Once those are loaded it starts a long download/update of over 3000 files. He says it will take around 20 minutes to complete. So hopefully here shortly I'll be ready to rock.
I convinced him to let me keep those files in case anyone else might need them. They prefer people call in for help so the device doesn't get messed up any further. I guess once they are too far screwed up then people have to mail them in.

Oh, and the root of the problem is their updater. My device is so old that the updater is unable to jump from my firmware to the latest without use of that LFU file. I'm not sure why they don't modify their updater appropriately, but there you have it.

...device updated successfully to the latest firmware. Took 27 minutes. Seems to be OK now. I'll verify after work.
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Old 05-12-2016, 02:56 PM   #109
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Re: sutyak's turbo 2004 Mach 1 build thread

That sucks! Yeah, I can remember reading a few others having issues like that because of their update. I remember that update took forever too.
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Old 05-14-2016, 03:13 PM   #110
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Re: sutyak's turbo 2004 Mach 1 build thread

Car is about ready to drive to Ocean City next week. Lubed the poly front control arm bushings, mounted front tires, covered the turbo and wrapped the downpipe, raised the front coilovers a bit more, and continuing to clean it up. Also tweaked the tune a bit to fix a lean spot at part throttle.

I took off the coolant tank to wrap the downpipe and found the plastic was very cracked and warped and leaking coolant from the heat of the turbo and downpipe. I ordered a Moroso aluminum tank, but for it to last a couple more days I cleaned it up and slathered on some high temp RTV. I'll just be pulling it in and out of the garage.





After wrapping downpipe.


Using energy suspension lube. Hands down the best lube for poly bushings. Bushings were completely dry.
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Old 05-16-2016, 08:59 AM   #111
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Re: sutyak's turbo 2004 Mach 1 build thread

Took the Mach to church yesterday. Lubing the front control arm bushings made a world of difference in ride, handling, and noise. Zero squeaks from the front now. I do have a rattle in the rear I need to investigate. I think it is one of the spherical bushings possibly not tight enough. I didn't completely fix the lean tip-in issue, so that is also on my agenda after work today.

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Old 05-18-2016, 09:05 AM   #112
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Re: sutyak's turbo 2004 Mach 1 build thread

Tune is basically lined out. If you have the SCT Pro Racer Package then you know your tune is never completely done since you can't stop playing with it. I'm sure it was good when it left Rev Auto, but who knows what the guy before me changed after he left. The lean tip in is completely gone, and I fattened up the WOT since it was a bit lean. General drivability is much better.
The aluminum Moroso coolant tank is in. Definitely one of the easiest parts I've ever changed on a car. It's a beautiful piece! I almost went with an ebay knock-off, but bit the bullet and spent a few more dollars and I'm glad I did.
I've had to do a significant amount of cleaning on this car. I have no idea how this guy got dirt where there is!



The tank touches the turbo blanket, but not too bad.




I also bought a set of Strange 10-way adjustable struts and 160# coilover springs from Aldan America. I'll swap those on before going to the track next month.
The car currently has 250# springs with what appear may be stock struts. Not so ideal for the track.
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Old 05-18-2016, 08:27 PM   #113
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The new tank looks really good.


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Old 05-18-2016, 08:42 PM   #114
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Re: sutyak's turbo 2004 Mach 1 build thread

Great progress!
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Old 05-23-2016, 09:29 AM   #115
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Re: sutyak's turbo 2004 Mach 1 build thread

Had an overall awesome trip to Ocean City this week. The car ran well for the most part. It takes forever to spool, but when it does it's a rocket. The car is just as fast as I had hoped, and that always helps to justify the purchase.
I had ongoing issues with overheating throughout the weekend. Turns out when I replaced the overflow reservoir it introduced air into the system somehow, or there was more coolant loss that I thought from the crack in the old tank. Either way, I screwed up later by not filling through the neck under the shaker and ended up with a nearly dry block. I didn't drive the car like that, and my buddy had to trailer it back for me. Long story short I simply had to fill through the proper bung under the shaker and not through the reservoir if the coolant is low. All seems well now. Next up I'll finish the trans and roll bar so I'll be ready to race in a month.





Not how I planned on getting home.
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Old 05-23-2016, 11:30 AM   #116
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Re: sutyak's turbo 2004 Mach 1 build thread

Over the next coupla days after car sits overnite, pull the bung and top off coolant, trapped air will rise and you will find you will keep having to adding. If you topped off reervoir, do NOT open it again. Eventually you won 't add anything. I have that same tank (painted of course lol), I had to wrap neck threads with teflon tape and screw cap on, I was getting air in the system thru that, a temp gauge for me was mandatory (Aeroforce), I knew I had air in system when out of the blue a normal running temp of 180 would hit 215. Great build and congrats
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2.3L Whipple,3.37 Upper,4 lb.lower, ID 1000 injectors,LCD cooling mod,Billetflow idlers,200A Alt,oil cooler delete with MMR adapter plate,MM oil filter kit,FrozenBoost Heat Exchanger Flowtech L.T., Maganaflow O/R X with Magnapacks, FRRP D.S.,T-56 with 26 spline input shaft and anti venom mod with reverse lockout box, FR steel flywheel,Spec Stage 3+,Moser 31 spline axles,FR 3.73 gear
Tuned by B.Kurgan
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Old 05-23-2016, 12:03 PM   #117
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Re: sutyak's turbo 2004 Mach 1 build thread

Great info, thanks!
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Old 05-27-2016, 10:29 PM   #118
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Re: sutyak's turbo 2004 Mach 1 build thread

While I'm waiting on a part to be machined for my new transmission I went ahead and pulled the stock one. I was told it had a SPEC 3+ in, but it certainly smoked when I laid on it. Turns out it is just a SPEC stage 1!
The trans is out. Next up is getting out the stubborn pilot bearing.
I'm also hoping to get the roll bar installed this weekend.

Just a little hot..




So long 10-spline trans.
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Old 05-27-2016, 11:27 PM   #119
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Re: sutyak's turbo 2004 Mach 1 build thread

Good update!
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Old 05-27-2016, 11:52 PM   #120
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Re: sutyak's turbo 2004 Mach 1 build thread

Great progress...my Spec 3+ has held up good so far. A stage 1 !! Man you pulled it in time, wouldn't last much linger.
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Old 05-28-2016, 02:21 AM   #121
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Re: sutyak's turbo 2004 Mach 1 build thread

Which roll bar did you go with?
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Old 05-28-2016, 07:55 AM   #122
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Re: sutyak's turbo 2004 Mach 1 build thread

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Which roll bar did you go with?
Maximum Motorsports 6 point with swing out door bars.
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Old 05-29-2016, 10:00 PM   #123
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Re: sutyak's turbo 2004 Mach 1 build thread

The blind bearing puller was well worth the trip to AutoZone. The pilot bearing came out in two phases. The inner needle bearing sleeve popped out, switched to a larger puller, and pulled out the rest. Ten minutes tops.
Interior is out and ready for me to start the roll bar install tomorrow.
Pulled the steering wheel since I have that 04 Cobra steering wheel, plus it gives me more room to maneuver the roll bar in and out of the car. I thought I could use my 3 arm puller, but no luck. I tried an actual steering wheel puller, but the bushing that goes over the tip was just barely too large. The aluminum threads pulled right out of the steering wheel. A 2 arm puller did the trick. The steering wheel puller would have worked fine if I had used a socket instead of the provided bushing.
I'm not sure what brand of throwout bearing was in the car, but it is junk. I went with National brand from Advance, and for the pilot bearing. It's a great looking piece with a fully machined face. The old one had significant play, and squealed quite a bit.
I also learned the Teksid block in my car has been repaired in a few places. One peace was completely broken off. The top I'm not sure what is up with, and the lower right looks like it may have been cracked. Fingers crossed no actual stress areas have been cracked previously. Surprises at every corner with this car.









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Old 05-29-2016, 10:38 PM   #124
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Re: sutyak's turbo 2004 Mach 1 build thread

wow, sorry to see the BS you keep finding.

As far as logging boost, do you have an EGR on the car still? I deleted mine and doing a little research it looks like you can use the EGR signal wire and set it up in livelink to log boost. My Aeroforce doesnt have a specific output wire for logging but Ive been told you can splice in another wire to the signal wire going to the gauge and run from that. I intend to give it a try
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Old 05-29-2016, 11:56 PM   #125
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Re: sutyak's turbo 2004 Mach 1 build thread

Are you going to put in the coolant mod on the back of the heads?

The block looks like someone dropped it.
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