Giving a 405 Sport Wagon another chance

8 minute(s) of a 111 minute read

Last few weeks were very busy for me so I did not have a chance to work on the cars :-(

This weekend I will start on Dash,heater core swap.

I will also order Ford Focus SVT 300mm front rotors as they have the same bolt pattern as Pugs 4x108 and use 2g DSM AWD front calipers. This will be great brake upgrade for the price.

4-17-2014

This made my day and no 17x9's for me this month :-(

5-3-2014

Heater core started to leak so it's perfect time and weather for Dashboard swap. 

Tomorrow I'll swap manual transmission pedals,cluch cable,heater core and all manual transmission shift linkages.

5-6-2014

Well parts car heater core has evidence of leakage and no one has new one in stock :-(

However I ordered new 91 one pice speedo cable,all shift linkages,shift pivot ball,clutch cables and petal clip.

I still need to bring 91 MI16 out of storage to swap over cluster and shift knob mechanism.

I have not look for international supplier yet. I could see if one out of 91 is good but I would like to have new one,as everything else will be new. Yes 406 is using same heater core.

Rabin I'm sure it can be repaired but side plastic part of it would be still old unit and all those years of hot coolant makes plastic very brittle.

5-8-2014

Replacing pedal assembly sucked,but at least it's DONE. I also replaced one pice 91 speedo,clutch cable and shift rod mechanism.

5-13-2014

It took me whole Saturday just to get glove box repaired. Those 405 glove boxes are nightmare to pull in and out and cheap plastic that brakes so easy made me very furious.

I end up having two glove boxes,both broken on opposite corners so I end up cutting them in the middle and bonding them together to end up with one good working glove box. Also glove box latch was broken but luckily one on 91 was in good working condition. 

After glove box repair everything else was straightforward install. I end up shortening shiftter rod to use DSM shift knob.

I also got 91 home to remove engine and gearbox,and that made 91's last ride :-(

5-17-2014

You guys are more then welcome to stop by today and help out with engine removal :-)

I'll buy you your favorite beer and Pizza.

5-18-2014

I got engine out of 91 today.I started late about 4:30pm and had it out by 9pm,I did it my self as usual :-)

Thomas wanted to stop by and help out but he's 89 Turbo broke down so he was busy trying to fix it.

I worked on a lot of grease engines but this one must to be in top three,this MI16 have lived hard life and was not worth saving. Everything needs attention and repair so I'm glad I made right decision to make it in to parts car.

Pictures.

5-20-2014

I removed all engine brackets today and shipped them out to powder coater and now I have clear excess to engine and transmission so I can give it nice wash. Here are few pictures of how horribly dirty this engine is. Also here is the picture of axle before and after,so far I have 6 hours in removing and cleaning parts.

One thing cought my eye on cylinder # 4 onside of the head was what appears to be JBweld where head bolt goes through... I scraped if of but did not see damaged engine block so I'm not sure what was all that about. I'll investigate more after I give it good clean.

It looks like head bolt threads is damaged....

5-26-2014

Few pictures of finished dashboard.

5-27-2014

Today I swapped fuel sending unit out of 91 MI16 to Wagon as the one in the Wagon did not work at all times. Also I got three door panels cleaned up and installed,drivers front door panel is cracked :-( I'll end up using one out of parts car.

I need to droop of headliner at upholstery shop but there is soooooo many things do to and so little time in a day :-(

5-29-2014

Headliner is at upholstery shop and good bye auto seat belts.

5-29-2014

I'll definitely do that André. This is what I did so far.

1) Removed A and top B pillars as they will no longer be needed.

2) Removed top auto seat belt mechanisam.

3) Removed auto seat belts module under front seat.

4) Removed wireing from auto seat belt module to top auto seat belt mechanisam.

5) Removed secondary seat belts (under the front seats)

6) Buckles remain the same.

For installation I will update once I have headliner back.

Door panels are done. I did the best I could with what I had and thank god for parts cars :-)

Also I got exterior mirrors done(thanks to 91 MI16)