T5 Clutch fork....

[Brian Clancy]

From Turbo Ford - in the same ballpark it seems as this discussion -- with link to pictures
https://turboford.org/thread-turbo-coup ... tch%2Bfork

Hoping helpful...

[thesameguy]

That's really great info, and makes a great deal of sense. Thanks for posting that, and it's incredibly timely!

[andyofcolumbusmerkur]

Try that Crown Automotive Throwout Bearing - J5361614 for 29 dollars on the four wheel drive hardware site. It says it's for 80-86 CJ (CJ5,CJ6,CJ7,CJ8) not sure why the turboford post says it must be from 80-82 CJ5 only. You can still get all the parts for any old Jeep, so I don't think it will be hard to get in the future. Or you could get some expensive hydro conversion kit, which may be smoother and last longer. Good luck making it work some way or another.

[timxr8]

...Still leaves the matter of swapping out the inner stub axles for RS 108mm's, though, as well as budget. I suspect Mike Oyler and TimXr8 might have some sources, or pieces in stock? Tim, what's your website for parts?...

I should really make one, just for my own reference really and to keep version control more...controlled.

As for the stub shafts: rebuilt OEM axle shafts are probably the best way to go unless you're making a lot of power. The stock CV joints are essentially BMW units, not like the VW ones. 100mm OD with a 25 spline shaft (VW are 33). Also, Cosworth ones are about 10mm shorter due to the wider stub shaft for the ABS ring on the Disc rear hubs (All hubs are the same depth for each kind with the Disc rear being longer than the Drum stubs).

[thesameguy]

Is there a source for high quality new or reman CVs to go back on stock shafts?

[john keefe]

After a lot of searching and cross-referencing, I replaced my 108mm CV's with 4 of these from here: https://www.autohausaz.com/pn/93033203400. Excellent quality. Interesting that they're the same used on the larger/heavier BMW's, and Porsche 911's. A good example of why reinvent the wheel if you're Ford UK trying to spec something that will last for rally/track.

Not sure what the difference is between these two, but if the VW Jetta stuff fits, then either one of these would be a source/option for the stock XR:
https://www.autohausaz.com/pn/191498103
https://www.autohausaz.com/pn/535498104 (right inner front)

There's plenty of listings there for BMW stuff, though I don't know which model you cross-reference to the XR.

Tim, sorry, I get confused on the difference between stub shafts, and stub axles (depending on what source one's reading). I'm going with "stub axle" at the diff. Re-drilling the stock stub axles for 108mm's would be easiest, but as you cautioned and as is my concern, I don't think that would last very long with this particular 5.0L. And, these GKN 108mm CV's are probably 5-7mm wider/thicker than a stock 100mm joint. I suspect the "plunge" might take care of that difference, though I'd prefer not to be wearing the CV's in at slightly different depths/loads, esp. if I switch back and forth between diffs to experiment.

[thesameguy]

Spoke with Modern Driveline a bit... god, I love them so much. They charge a fortune but they respond thoroughly and thoughtfully to questions. It's so worth it.

They recommended a competitor's product:

https://www.mcleodracing.com/conversion-kits--ford/p89

This is an interesting kit in that it uses a pull-type master cylinder (very unusual) and basically a non-adjusting clutch quadrant to move it. Theoretically, it could be pretty bolt in.

I think it would fit, but I'm not sure how to feed it. I don't know there is enough vertical clearance to put the remote reservoir above the master cylinder.

I also found this:

https://www.summitracing.com/parts/awr- ... gKta_D_BwE

Which is kinda neat - it allows the master cylinder to be mounted at an angle on the firewall. Not a necessary component, but if I do mount a Wilwood directly, it could make the process easier.

[thesameguy]

Not sure what the difference is between these two, but if the VW Jetta stuff fits, then either one of these would be a source/option for the stock XR:
https://www.autohausaz.com/pn/191498103
https://www.autohausaz.com/pn/535498104 (right inner front)

I think the problem with these is the spline count or diameter - Tim observed the spline count for Ford vs VW is different - 33 vs 25 spline. That said, my VW buddy (he has a crazy turbocharged VR6 MkIII Golf) indicated that MkIII cars use a 25mm, 22 spline CV but later car use a 28mm 33 spline CV.

Because I am ignorant: When you say 108mm, are you referring to the bolt circle, or the OD of the CV?

Using what Max told me, I'm able to find things like:

https://www.kartek.com/parts/gkn-stock- ... -1979.html

I'm not doing *$#!** with axles at this point as I gotta get the transmission issue sorted out... but I do want a plan for when my Chinese axles break.

[john keefe]

108mm is the bolt pattern. 3mm wouldn't seem like much, but the overall dimensions of the 108mm are a lot beefier than the stock 105mm for heavier or high performance applications.

[thesameguy]

Now I'm more confused... Are we talking about:

wheel bolt pattern? 4x108/XR vs 5x108/Scorpio

CV bolt pattern? 6x100 XR vs ???/Scorpio

CV OD? ???/XR vs ???/Scorpio


It *seems like* with these German CVs there are several critical dimensions:

Bolt pattern (XR is 6x100 *I think*)
Bolt hole diameter (XR is 8mm)
Thickness
OD
Spline count (XR is 33 according to Tim)
Shaft Diameter

I think I have a loose XR CV at home... I'll measure it to fill in the blanks.

[john keefe]

Sameguy... 6x108 on the CV/stub bolt diameter (vs. 6x100 for stock XR). When I repacked and re-booted the Scorpio CV's, they were the same, smaller sized CV and 6x100mm bolt pattern as the stock XR. I don't know if you can get a good idea of the size difference, but do a comparison with the pics in the links I sent for AutohauzAZ. Sorry, been a long while since I had to deal with the stock XR CV's, or I might be of more help with the dimensions/splines et al.

[thesameguy]

Gotcha, that makes sense. There were enough 108s going around I wanted to be sure I what we were talking about.

I have all the stock pieces in the garage I can measure. After talking with Max I have higher hopes that quality, durable CVs are out there... it's just a matter of knowing the specs. No surprise, but there's enough of a VW tuner crowd out there that lots of custom/stronger parts exist... hopefully in the right dimensions for the XR!

On the topic of the clutch, let me also mention:

https://apracing.com/race-car/master-cy ... on-mounted

AP Racing makes two pull-type master cylinders. I think this could be made to work similarly to the Mcleod setup, using either a modified stock quadrant or the DG manual one I've already got. But, uh, it's like $500. So, you know, not really a win. But maybe there are others out there... that aren't for motorcycles.

Apparently it's supposed to rain here all weekend, which means cutting up cardboard and taping it to my engine bay isn't gonna happen. Boo.

[thesameguy]

Well, it ain't raining yet!

Made some cardboard bits to mark out where parts might go...



Going down this road, I will also relocate the wiring harness to run down the side of the engine bay rather than down the frame rail. Not any particularly good reason for this, but it'll help keep the wiring away from heat, and from becoming a receptacle for goop that comes off the engine. Anywho...



I think there is BARELY enough room to tuck the Wilwood master cylinder down there..... My cardboard is very close to exactly right. I am less sure about clearance for the fluid inlet and outlet. But, after talking with MDL, I can safely rotate the MC 45 degrees and it'll be fine, and that I think solves my issue.

If I go forward with this, this is where the MC would attach to the pedal. Quite a bit lower than I'd like which would no doubt lead to increased effort and less travel.... so I'm not sure this is a good plan.

Some more things to try and look at... but I feel like I'm pretty committed to this path at this point.

[andyofcolumbusmerkur]

$580 Nice but pricey


$20 But for the wrong year (could modify to work?)
68-73 CLUTCH FORK RETAINER CLIP REPAIR KIT


$17.63 Shows in stock, but who knows. Gotta be some out there someplace.
Ford Part No.:E6ZZ-7515-A

https://www.fordpartsgiant.com/oem-ford ... _fork.html
https://www.fordpartsgiant.com/parts/fo ... 515-a.html

[john keefe]

That remote-mount reservoir would solve a lot of issues. Other than installing some sort of reinforcement plate on the firewall for the MC, looks like the Mustang clutch quadrant would adapt right in to the XR pedal assembly. Having a little trouble picturing how that MC stays put in that teflon-lined firewall mount, though (the round bracket with the cup/receiver for the lever end of the MC).