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ford ef falcon futura wagon xr6 hybrid 

 

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 Post subject: ford ef falcon futura wagon xr6 hybrid
Posted: Fri Jul 11, 2014 10:14 pm 
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hey guys I know this is probably in here somewere but I couldn't find it and wasn't gunna hunt through hundreds of threads in a attempt to stumble across it lol, so I hope you don't get asked this question to much that me asking just becomes a inconvenience.

we have a 1995 ford ef falcon future wagon the engine has done 322,170ks which I understand is more than there life span, the diff is leaking oil like a oil tanker after hitting a iceberg and the trans is nowere near as responsive as it was when we bought the car. the cars been in our family since 2001 and we are the second owners of the vehicle previous owner was a elderly gentleman who bought the car off the showroom floor. I don't drive the car often its mums I own a R33 skyline and a GQ patrol and mum loves the car and wants to keep it but is getting bored of the same old and now it needs to be given life I thought it might be a chance for a upgrade.

a close friend has a 1996 ef xr6 which was just declared a ride-off due to a tree branch falling on the roof and across the boot and is willing to sell me the car for $600 if my idea can be done.

what im hoping to do if possible is take the engine, diff, trans ect from the xr6 and transplant them into the wagon is this possible and what is required to do this job. also is engineering required???

any help and insite from fellow members would be much appreciated and I look forward to reading your replies cheers, scithe93
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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Fri Jul 11, 2014 11:47 pm 
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Yeah it possible I think the only issue your going to have is the tail shaft on the wagon is longer than the sedan (feel free to correct me on this). Just be sure to take the ecu as well, and maybe some interior bits and transplant them . If your really up for a challange change the front end of the wagon to the XR one, might need a respray but it would look pretty sweet. XR wagons are rare as hens teeth. So I would say take as much as you can from the XR and put it on the wagon.

 

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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Sat Jul 12, 2014 7:34 am 
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its all bolt in, plug and play, diff, eng gearbox and tranny.. use the xr loom (no different but anyway) as it will already be on the xr motor when you pull it, and drop it into your wagon, stick the ecu in and happy days..

and at 323k if its been looked after should be fine..

mine just hit the milestone of 350k 2 days ago, stock untouched bottom end, and im still pushing 185psi out of each cylinder, and no bottom end knocks yet..

a mate of mine has an EF with no word of a lie, 700ks on it, its still going today..

 

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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Sat Jul 12, 2014 8:09 am 
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Engine is a direct swap. Replace the rear mainseal while you have the engine out and check welch plugs and seal. Also check the sump gasket. Use the XR6 ECU as it will match up to the cam etc.

Gearbox if auto to auto is a straight up swap. Change the front seal on the box before fitting up. Drain all the oild and give it a service before you put iy in and drain the Convertor as well. Use an air hose on low pressure to blow the trans lines out before fitting. If you are swaping in a manual, you will have further work to do.

Sedan diff WILL NOT bolt up to a wagon. Take both diffs to a diff place and have them put the 3.45LSD into the wagon diif and away you go.

Front end is an easy bolt up. Front bar, headlights, indicators etc. Bonnet is exactly the same as the GLi/Futura one except it has the vents. If you want to save money on the paint, leave to original bonnet on.

322,000 km is nothing on a 4.0 that has been looked after.
Are there any issues with the engine that is in the wagon?
How many Km on the XR engine?
How has the XR Engine been treated?
When was the gearbox in the wagon last serviced?
Where is the oil leaking on the diff in the wagon?
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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Sat Jul 12, 2014 4:45 pm 
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yeah putting the xr front end on and found xr style side skirts for wagons on www.carmate.com
want as much xr as I can coz there rarely seen in a wagon, biggest mistake ford made imo.
il have to research into the tailshaft but im pretty sure your right about it being longer, yes it will be auto to auto she only has a auto lisence so I couldn't be mean and put a manual in hahaha.

I plan on taking the ecu and wiring loom from the xr along with any other bits I can transplant.
the engine in the wagon is leaking from all around the sump and the front end, also lifters keep sticking and injectors are fouled to the max, apart from that the heads on its way out. wagon was serviced every 10,000ks up until a few years back when I moved outta the state for some work and had to keep reminding mum to check oil and water levels ect and book services. came back and brakes were metal to metal with warped disks engine was bone dry and fuel filter hadn't been replaced in the whole 3 yrs I was gone :| not good. last proper service on wagons trans was back in 09 but I always check fluid levels and keep them up. the diff in the wagon is leaking from the bottom end I think it bounced off a rock at the bottom of the driveway and cracked but unsure.

the xr was looked after well serviced everytime the light came on but was given a lil bit of a go every now and again as all young fellas do lol, it has less than 200,00ks I know that much think its around 180 something.

a few more questions before I decide to move forward with the project.

will the LSD centre just fit straight into the wagon housing?
is there much difference between the xr auto and wagon auto?
would it be possible to bolt up a BA sports auto to the ef XR engine, ect?
will the xr dash be a straight swap into the wagon? or should I leave the dash and just change cluster?
can a xr rear bar be modified to fit a wagon?
are the front doors the same in wagon as xr? can the rims just swap over?
will engineering be required to do the engine trans and lsd?
would it be worth reconditioning the xr engine and trans before fitting them in the wagon?

I work as a 4wd mechanic and the boss has said I can use the hoist and tools at work to save myself some dollars.

ive worked on a few old carby fords like my old xe and friends xc ute but never worked with ford injected engines and being mainly 4wd and import orientated has got me in a bit of a confusion but if this all works out I think more fords will be on the future agender lol. cheers for all the help fellas
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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Sat Jul 12, 2014 5:25 pm 
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Q) il have to research into the tailshaft but im pretty sure your right about it being longer, yes it will be auto to auto she only has a auto lisence so I couldn't be mean and put a manual in hahaha.
A) Wagon & Fairlane/LTD tailshaft is long wheel base, sedans are short wheel base. You already have a tailshaft in the wagon to use.

Q) I plan on taking the ecu and wiring loom from the xr along with any other bits I can transplant.
A) Engine Wiring loom is the same for GLi/Futura/XR6. No need to swap the loom over. Just leave the existing loom on the new engine and plug it into your existing engine bay loom.

Q) the engine in the wagon is leaking from all around the sump and the front end, also lifters keep sticking and injectors are fouled to the max, apart from that the heads on its way out. wagon was serviced every 10,000ks up until a few years back when I moved outta the state for some work and had to keep reminding mum to check oil and water levels ect and book services. came back and brakes were metal to metal with warped disks engine was bone dry and fuel filter hadn't been replaced in the whole 3 yrs I was gone :| not good. last proper service on wagons trans was back in 09 but I always check fluid levels and keep them up. the diff in the wagon is leaking from the bottom end I think it bounced off a rock at the bottom of the driveway and cracked but unsure.
A) Replace the lot then and do as I said with the above post on replacing things on the engine/gearbox.

a few more questions before I decide to move forward with the project.

will the LSD centre just fit straight into the wagon housing? Yes
is there much difference between the xr auto and wagon auto? Same auto BTR 93/97LE
would it be possible to bolt up a BA sports auto to the ef XR engine, ect? Do you mean an XR Tubo BTR 4 speed? Not worth it, your mum will never have enough power to need it and you will have issues with the speedo output as well as the shifter link. BA is cable shifter link and speedo is taken off the rear ABS ring
will the xr dash be a straight swap into the wagon? Only difference with the dash itself is the cluster and the dash spear.or should I leave the dash and just change cluster? Just change the cluster, you will need to ensure that the oil pressure sender on the doner engine is good.
can a xr rear bar be modified to fit a wagon? http://www.awcinfo.com//secureshop/category.php?cat_id=79 rear skirt EL017 Fiber sports, http://www.carmate.com/display_products ... egoryid=12 Carnmate. You could try and modify an EF/EL sedan rear skirt but not worth the hassel.
are the front doors the same in wagon as xr? Yes
can the rims just swap over? Yes
will engineering be required to do the engine trans and lsd? No, Blue slip for the new engine number
would it be worth reconditioning the xr engine and trans before fitting them in the wagon? Depends on the condition of the engine and gearbox.
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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Sat Jul 12, 2014 9:32 pm 
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cheers for that mate,
so I should just clean up the wagon tailshaft and replace the joins maybe even give it a respray black and then use it.

so use the xr engine loom and hook it up to the current engine bay loom in the wagon.
so being mechanically minded could I change the diff center's over myself or is it worth paying a licensed mechanic to do?

I meant the ba xr6 na sports auto but there the same if im correct, with the trans being the same between wagon and xr and it not being worth the hassle with the ba how can I increase shift times or is it not worth doing?

so just change the cluster over and replace oil pressure sender just to be on the safe side, none of the switches are different? i thought xr had elec front and rear windows were as wagon just has elec front. is it a straight swap for the steering wheels?

so the only difference in front doors is the trims and there a straight swap, what about rear doors? sorry that was ment to say trims not rims before but I want the sharkfin rims aswell.

yeah I saw the xr style add on lip when I was on carmate so I think il just do that and cut exhaust hole bigger if needed to fit a twin tip.

I think il just recondition the lot engine trans and diff start with a freshish powerplant. is there a way to wind the odometer so it reads the ks on the xr engine or will the ecu do that?

im from vic and when I changed my skyline from n/a to turbo I done it with a engine swap and vicroads required engineering report wouldn't this be the same goig from basic ford engine to xr tickford engine? also wouldn't the diff need engineering changing it to LSD? I know I needed engineering when putting Detroit lockers in my 4wd.


a few last questions just so im clear on everything here.

is the front end suspention the same on the wagon as the xr?

are the front and rear brakes the same on the wagon as the xr? or are the xr calipers and disks larger. also is there any difference in the brake master cylinder and booster?

is there a way to convert the wagons rear suspention from leaf to coilsprung like in the xr?

are the swaybars the same in wagon as in xr?

is there anything im missing or forgetting???
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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Sat Jul 12, 2014 9:57 pm 
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NSW, Australia

so I should just clean up the wagon tailshaft and replace the joins maybe even give it a respray black and then use it. Just use the Wagon tail shaft, they are alloy anyway.

so use the xr engine loom and hook it up to the current engine bay loom in the wagon. Yes
so being mechanically minded could I change the diff center's over myself or is it worth paying a licensed mechanic to do? Diff specalist in my book unless you have done it before.

I meant the ba xr6 na sports auto but there the same if im correct BA XR NA auto is the same a an XT Taxi, with the trans being the same between wagon and xr and it not being worth the hassle with the ba how can I increase shift times or is it not worth doing? Shiftkit, but I thought this was your Mum's car.

so just change the cluster over and replace oil pressure sender just to be on the safe side, none of the switches are different? Just change the cluster. i thought xr had elec front and rear windows XR has front pwer windows as per the Futura. XR is based on the Futura. were as wagon just has elec front. is it a straight swap for the steering wheels? Yes

so the only difference in front doors is the trims and there a straight swap, what about rear doors? Straight swap for all sorry that was ment to say trims not rims before but I want the sharkfin rims aswell. Rims fit any E series

yeah I saw the xr style add on lip when I was on carmate so I think il just do that and cut exhaust hole bigger if needed to fit a twin tip.

I think il just recondition the lot engine trans and diff start with a freshish powerplant If you want. is there a way to wind the odometer so it reads the ks on the xr engine or will the ecu do that? Cluster retains the odometer reading

im from vic and when I changed my skyline from n/a to turbo I done it with a engine swap and vicroads required engineering report Because you went Turbowouldn't this be the same goig from basic ford engine to xr tickford engine? No, it is still a stock 4.0L, only blueslip required for engine change.also wouldn't the diff need engineering changing it to LSD? No, factory optionI know I needed engineering when putting Detroit lockers in my 4wd.


a few last questions just so im clear on everything here.

is the front end suspention the same on the wagon as the xr? XR has lower springs (equeal to King lows

are the front and rear brakes the same on the wagon as the xr? Yes or are the xr calipers and disks larger No The same. also is there any difference in the brake master cylinder and booster XR is same as GL1/Futura/Fairmont sedan, Wagon master cylinder is different bias to the sedan?

is there a way to convert the wagons rear suspention from leaf to coilsprung like in the xr? NO

are the swaybars the same in wagon as in xr? No, Seadn is coil suspension and wagon is leaf springs Swaybars are the same across the front whether the car be sedan or wagon, GLi or XR

is there anything im missing or forgetting???[/quote] I am sure you will think of something.
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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Sat Jul 12, 2014 10:45 pm 
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nah never changed a diff center before so I guess il leave that one to a specialist, yeah it is mums car but I do a lot of the driving for her since I moved back home due to the fact she cant see at night properly and has trouble focusing on the rd also mum is abit of a leadfoot so faster shifts would be a good upgrade for both her and me lol.

ok so how would I go about doing electric windows in the rear would the rear doors from the xr fit the wagon or are they different sizes?

so the xr cluster will have the accurate odometer reading for the engine, what about the trip computer can that just transfer ove???

so the calipers and rotors are the same, I should just upgrade the rotors to slotted and put better pads in. also just leave the front suspention setup of the wagon and replace shocks springs and bushes? so I cant change the rear suspention il just replace the shocks, bushes and would it be worth putting in new leaf springs?

so no engineering will be required just bolt and go?

are the radiators the same size? would it be worth investing in a external oil cooler?

isn't the xr throttle body larger would it just bolt straight up?
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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Sat Jul 12, 2014 11:32 pm 
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scithe93 wrote:
nah never changed a diff center before so I guess il leave that one to a specialist, yeah it is mums car but I do a lot of the driving for her since I moved back home due to the fact she cant see at night properly and has trouble focusing on the rd also mum is abit of a leadfoot so faster shifts would be a good upgrade for both her and me lol.

ok so how would I go about doing electric windows in the rear would the rear doors from the xr fit the wagon or are they different sizes?

doors are differant - just change the window regulators [what winds glass up/down] plus fit extra wiring etc

so the xr cluster will have the accurate odometer reading for the engine, what about the trip computer can that just transfer ove???

i don't no

so the calipers and rotors are the same, I should just upgrade the rotors to slotted and put better pads in. also just leave the front suspention setup of the wagon and replace shocks springs and bushes? so I cant change the rear suspention il just replace the shocks, bushes and would it be worth putting in new leaf springs?

always good to upgrade brakes ... with suspension _ replace/upgrade whats needed

so no engineering will be required just bolt and go?

for what you have asked? - no/yes bolt n go

are the radiators the same size? would it be worth investing in a external oil cooler?

yes [as far as i know BUT i'm no expert] & yes

isn't the xr throttle body larger would it just bolt straight up?

i don't know
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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Sat Jul 12, 2014 11:41 pm 
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sweet sounds like itl be a lot easier than I thought
and the ef xr6 throttlebody is 89mm im pretty sure the standard ef is only 85mm but not 100% il have to measure when I pick the xr up from my mates. cheers guys il keep ya updated on my progress
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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Sun Jul 13, 2014 7:20 am 
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nah never changed a diff center before so I guess il leave that one to a specialist, yeah it is mums car but I do a lot of the driving for her since I moved back home due to the fact she cant see at night properly and has trouble focusing on the rd also mum is abit of a leadfoot so faster shifts would be a good upgrade for both her and me lol.
If you want to alter shift points, then fit a shift kit.

ok so how would I go about doing electric windows in the rear would the rear doors from the xr fit the wagon or are they different sizes?
XR's do not have power windows from factory. If you want to fit rear power windows, you will need to source some rear regulators and add the wiring, part of the loom will be there if there as the wagon is a Futura and should be fitted with cruise control.

so the xr cluster will have the accurate odometer reading for the engine, what about the trip computer can that just transfer ove???
XR's do not come with a trip computor, you will need to source one and fit the wiring.

so the calipers and rotors are the same, I should just upgrade the rotors to slotted and put better pads in. also just leave the front suspention setup of the wagon and replace shocks springs and bushes?
Front suspension on the XR is the same as the wagon except for the springs and struts.

so I cant change the rear suspention il just replace the shocks, bushes and would it be worth putting in new leaf springs?
You can fit the XR front springs to the front and use lowering blocks on the rear or get reset leaf springs. Or you can leave the rear alone and have raked stance like old school.

so no engineering will be required just bolt and go?
For the umptenth time. NO ENGINEERING REQUIRED, just a blue slip for the engine number change.

are the radiators the same size?
Radiators are the same

would it be worth investing in a external oil cooler?
Auto cooler, yes, if the wagon is fitted with a factory tow pack, it will have an auto cooler from factory. Engine oil cooler, waste of time on a stock motor.

isn't the xr throttle body larger would it just bolt straight up?
Throttle body is the same for all EF/EL I6

The only mechanical differences between an XR6 & a GLi/Futira are:
1) Head
2) Cam
3) ECU, to allow for cam, diff ratio, fuel maps, etc.
4) Lower suspension (equeal to King Lows).
5) 3.45.1 Diff ratio.
6) Alloy tail shaft.
7) Slightly larger exhaust. Exhaust manifold is the same as the GLi/Futura.
8) XR/Fairmont Cluster.
9) Nose cone and lights as well as vented bonnet.
10) Coloured body molds and badges.
11) Optional Body Kit.
12) Seats.
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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Wed Jul 30, 2014 1:22 am 
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its been a while but I have all the parts out of the xr6 just some cleaning and small repairs to do then the car gets the transplant.

well the xr6 I got as the donour car had a trip computer and rear power windows the trip and climate control weren't in the best shape had crack ect so im replacing them link to the items im buying on ebay below. does this mean these are not factory fitted or were they optional extras.

http://i.ebayimg.com/00/s/NjQwWDY0MA==/$T2eC16ZHJGwE9n)yUZE1BQsJJRCL2g~~60_57.JPG

http://i.ebayimg.com/00/s/NjcyWDU0Mw==/ ... n/$_57.JPG

apart from that ive had the original transmission reconditioned, had the original wagon diff housing cleaned up and resprayed black then the lsd center put in and hit the tailshaft over with a wire brush to clear off all surface rust, the engine is currently being reconditioned and may be getting a bigger cam put in haha, I bought a full steel 3 core radiator to replace the stock one with plastic tanks, have whiteline front and rear swaybars, Monroe sense trac gas shocks and standard hight kingsprings for the front along with nolethane suspention bushing kit and looking for oem standard king spring leafs for the rear front dba slotted rotors and dba standard rear rotors with thermo quiet pads front and rear, had to buy a 2nd hand brake master cylinder and booster as the wagons booster had a hole in it and was sucking in air and the xr one didn't fit, got a reconditioned power steering pump, all new rubber lines and hoses (brake, power steering, ect) a new 110amp alternator new belts pretty much got everything I need just waiting for the engine to be finished to pick up then I can start transferring everything in the wagon. instead of getting a respray im sending it off to have the whole car vinyl wrapped in gloss white once done. I picked up some performance headers/extractors a hi flow cat new front muffler and a varex rear muffler w/ twin 3inch tip unfortunately my grandma passed away recently so that put me behind sceduale but am hoping to be back on track soon, as much as its a sad thing mums using some of her inheritance to buy a new car so im buying the wagon off her for $500 as a nice little project, got sports seats for the front and the same material to reupholster the rear seat got black moulded carpet and am getting the interior vinyl wrapped in black and brushed stainless and have bought a nice sound system for the beast. I think that's about it but yeah I have practically everything I need now just need the time to start the transfers but that's a update to were I am in the build hope everyone elses projects and toys are coming along as smoothly as mine is will keep ya updated guys and will check in every night or few nights to see any coments. if you have anything to add or think I missed something fel free to comment im always open to extra advice and opinions. :D pics will come as I start the transplant

EDIT: forgot to add im in this project about $5000 so far hoping to keep it under 7-7.5 but we will see
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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Wed Jul 30, 2014 6:08 pm 
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[quote="scithe93"]its been a while but I have all the parts out of the xr6 just some cleaning and small repairs to do then the car gets the transplant.

well the xr6 I got as the donour car had a trip computer and rear power windows the trip and climate control weren't in the best shape had crack ect so im replacing them link to the items im buying on ebay below. does this mean these are not factory fitted or were they optional extras.

XR's did not have factory fitted trip computor nor did they have climate control. These were fitted to Fairmont upwards.

http://i.ebayimg.com/00/s/NjQwWDY0MA==/$T2eC16ZHJGwE9n)yUZE1BQsJJRCL2g~~60_57.JPG

http://i.ebayimg.com/00/s/NjcyWDU0Mw==/ ... n/$_57.JPG

apart from that ive had the original transmission reconditioned, had the original wagon diff housing cleaned up and resprayed black then the lsd center put in and hit the tailshaft over with a wire brush to clear off all surface rust,
Should be no rust on a wagon Tailshaft other than the uni jpoints as they are alloy.

the engine is currently being reconditioned and may be getting a bigger cam put in haha, I bought a full steel 3 core radiator to replace the stock one with plastic tanks,

No such thing as a steel core radiator. it is either copper or aluminium.

have whiteline front and rear swaybars, Monroe sense trac gas shocks and standard hight kingsprings for the front along with nolethane suspention bushing kit and looking for oem standard king spring leafs for the rear front dba slotted rotors and dba standard rear rotors with thermo quiet pads front and rear, had to buy a 2nd hand brake master cylinder and booster as the wagons booster had a hole in it and was sucking in air and the xr one didn't fit,

You need to ensure that you got a wagon Master cylinder as the wagons had a different bias to the sedans. Brake booster is the same for wagon or sedan, XR or std.

got a reconditioned power steering pump, all new rubber lines and hoses (brake, power steering, ect) a new 110amp alternator new belts pretty much got everything I need just waiting for the engine to be finished to pick up then I can start transferring everything in the wagon. instead of getting a respray im sending it off to have the whole car vinyl wrapped in gloss white once done. I picked up some performance headers/extractors a hi flow cat new front muffler and a varex rear muffler w/ twin 3inch tip

You will have fun trying to fit the Varex in the rear section of the wagon, good luck with that.

unfortunately my grandma passed away recently My condolaces on your loss so that put me behind sceduale but am hoping to be back on track soon, as much as its a sad thing mums using some of her inheritance to buy a new car so im buying the wagon off her for $500 as a nice little project, got sports seats for the front and the same material to reupholster the rear seat got black moulded carpet and am getting the interior vinyl wrapped in black and brushed stainless and have bought a nice sound system for the beast. I think that's about it but yeah I have practically everything I need now just need the time to start the transfers but that's a update to were I am in the build hope everyone elses projects and toys are coming along as smoothly as mine is will keep ya updated guys and will check in every night or few nights to see any coments. if you have anything to add or think I missed something fel free to comment im always open to extra advice and opinions. :D pics will come as I start the transplant

EDIT: forgot to add im in this project about $5000 so far hoping to keep it under 7-7.5 but we will see
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 Post subject: Re: ford ef falcon futura wagon xr6 hybrid
Posted: Sat Aug 02, 2014 2:31 pm 
Fordmods Newbie
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Age: 24

Posts: 18

Joined: 9th Jul 2014

Ride: ef falcon futura

Location: melbourne
VIC, Australia

firstly thank you for the condolences, this car is keeping me pre occupied so I don't think about it to much apart from that were coping fairly well.

so the climate control and trip were installed in the xr aftermarket, the ones in the xr are damaged due to my mate being rough getting is sound system out and stuffing the whole dash. so I bought new ones but a thought just occurred will they be able to work with the wagon? and how much fiddling will there be getting them to work.

yeah it was surface rust on the unis and orangish brown speckles on the shaft itself I thought these were surface rust either way cleaned up nicely must of been clay and mud that settled there.

well a full alloy radiator then, its all metal no plastic tanks and all black hoping it will work well matched with silicone hoses.

yeah took the master off a wagon at the wreckers just hoping it wont have the same issue as the original one did.

why will I have trouble with the varex? il make it fit and work somehow hahaha
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