S197 Hybrid - 2006 Mustang with S550 guts

[spedy7]

The end caps of the metal frame in the dash that attach to the A pillar will need modifications but no plastic should need to be cut. Hard points for the HVAC appear to be in the same place as well, they just moved the connections over so minor firewall mods will be needed.

For now I’m keeping the solid axle but the plan is in the future to figure the IRS out. Again, I know it can be done!

If Ford did it, so can you lol. Sounds like plans for a proper usable car if you're also swapping the hvac housing. Might be able to graft some sheet metal from a wrecked S550 firewall to make things easier? Curious about the 10R80 mounted to a 5.2 too - I've never heard this being done before. It'll obviously bolt up to the block, but would a special flex be needed as well as programming? Or just winging it for now?

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[zackmd1]

If Ford did it, so can you lol. Sounds like plans for a proper usable car if you're also swapping the hvac housing. Might be able to graft some sheet metal from a wrecked S550 firewall to make things easier? Curious about the 10R80 mounted to a 5.2 too - I've never heard this being done before. It'll obviously bolt up to the block, but would a special flex be needed as well as programming? Or just winging it for now?

Yea the goal is a fully functional car, no warning lights. 07 GT500 on the outside, S550 on the inside.

Bellhousing bolt pattern, crank bolt pattern didn’t change from a normal coyote so a 10r80 should bolt right up like it was behind a coyote. People have done 6r80 swaps in 350s and the 10r80 interface is no different. Also confirmed with a tuner that a Gen 3 PCM should be able to run a 5.2.

 

[Epiphany]

Great project, looking forward to seeing how it plays out. Just wanted to comment on the ribbed aluminum intake assembly. I searched far and wide for one for my Fox body. I looked at every one out there and decided on the same one I see you chose for your Cobra. Robust with rather thick aluminum, I found a red filter for it and refinished it in all black. Nice choice!

 

[zackmd1]

The previous owner of these heads was not kind to them. Based off of the spark plug gaps, it was a boosted application which explains why there are small bits of piston in the exhaust port of one cylinder and two bent exhaust valves. Just enough knowledge and money to be dangerous.... They were sold as "Used, no issues". Dropping them off at the machine shop Monday.

 

[zackmd1]

The disassembly has begun!

 

[fmc_smt]

The previous owner of these heads was not kind to them. Based off of the spark plug gaps, it was a boosted application which explains why there are small bits of piston in the exhaust port of one cylinder and two bent exhaust valves. Just enough knowledge and money to be dangerous.... They were sold as "Used, no issues". Dropping them off at the machine shop Monday.

With all that gauging in the matting surface I would be concerned.

 

[xr4x4ti]

Very cool project. Watching.

I have a soft spot for the 10-12 body style (to each his own) but went with an s550 to get the IRS, interior, etc.

 

[zackmd1]

With all that gauging in the matting surface I would be concerned.

Should be able to fill then deck without much issue. But if for some reason that’s not possible, the rest of the parts (springs, valves, etc…) are worth what I paid and I can get new cores.

 

[zackmd1]

Comes apart easy when the goal is for it to come apart!

 

[Strokerswild]

Very cool project, I'll be watching this one.

I only owned my '09 Bullitt for about a year before ordering my '15, and having had my '07 GT500 for several years prior I found it a little underwhelming in terms of power. I pondered a Coyote (Boss) swap, but was told it couldn't be done. Not to mention the mental cardinal sin of hacking up a pristine, low-mile Bullitt. However, it would have been a very nicely balanced car all around, I preferred the Bullitt's chassis finesse over the Shelby's and a tuned Boss 302 would have been the sweet spot for power, I think.

Nice Cobra too!

 

[zackmd1]

About as disassembled as it needs to be. Good thing I pulled the carpet as it was completely soaked underneath. Must have had a hell of a leak at one point or the windows were left down during a storm. Scrubbed down with a bleach solution and its ready for assembly!

 

[ILStang]

Awesome! Looking forward to watching this progress.

 

[zackmd1]

Could someone with forscan do me a favor? Is it possible to go into the RCM and “disable”/tell it no side curtain airbags are installed? Obviously don’t plan on fitting the side curtain airbags and will either need to run a resistor or disable them through forscan if it’s possible.

 

[zackmd1]

Well first major discovery…. Ford changed the windshield curvature between S197 and S550 generations. S550 is slightly more curved, center more forward with the corners farther back. Means some slight trimming to the dash plastic will be required to make it fit. But as a teaser!

 

[MidnightStars]

Hard to even tell it needs adjusting!
But man, your work is tempting me into eventually gutting out my S550 for S650/S750 internals!

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