A4ld to m5od r1hd swap wiring

[highstakes]

Hey all, I've been a long time lurker here but haven't done much posting

91 4.0 4wd xlt with factory electric t case and automatic trans

I swapped my t case to a manual out of a b 3000 a year ago without connecting any of the wires but the 2 pin connector right next to the speedo cable.

Now my a4ld has gone out. I have all the old stuff out and the new trans and hydraulics and a modified pedal in.

However, it refuses to turn over. The starter relay clicks and the t case shifter tries to weld itself to the cab. I have the pink and red/blue wire from the a4ld spliced together. Stock computer and no wiring done anywhere except those two wires that used to be part of the 5 pin plug on the trans. Any thoughts?

 

[RobbieD]

The starter relay clicks and the t case shifter tries to weld itself to the cab.

That sounds like you have a problem with the main grounding cable, between the battery negative post and the engine block.

 

[SenorNoob]

Definitely sounds unrelated to the swap except for of course that you had to swap starters. Double check those connections.

 

[highstakes]

Did i have to swap starters? My existing one bolted in so i kept it. It didn't quite fit like a glove and i had to get rid of the little automatic plate that goes between the trans and the motor because it rubbed on the flywheel but otherwise I would think the starter would still ground. Do autos and manuals have different starters? If the relay is engaging wouldn't the starter be getting power? I haven't had time with work but I will have a block of time tonight to go back and check on the state of things

 

[SenorNoob]

Yes. 4.0 auto and manual starters are different. The auto starter is designed for a smaller diameter ring gear.

You're gonna need the starter and the spacer plate from a 4.0 manual. Without that plate there is enough wiggle room on the starter that it'll chew up the flywheel and starter.

 

[highstakes]

Well crap. I can get a new starter, that's not too bad, but that plate is a little bit bigger of an issue. I can't really find them online and I have everything 100% back together. The bolt holes in the trans and the the little lip on the face of the starter won't secure it enough? I have access to a band saw and a drill press so I could make something if I really have to

 

[SenorNoob]

Locating the starter is the entire purpose of that plate.

Not saying it is impossible to make something else work... Just difficult.

 

[highstakes]

Ok, were all set now. The auto starter must have been butted up against the flywheel, because it starts and drives great with the manual starter and those two NSS wires spliced. The r1hd feels great too. However, for some reason, my brakes are squishy. They still work almost as good as they did before, but the top half of the pedal is all slop. I found a real long downhill and my brakes were smoking by the end of it. My abs light hasn't come on at all and I put the truck in the air to test the rear brakes and they work fine. Any ideas? I'm going to try bleeding them next chance I get. I blocked off the trans vac line that the a4ld had.

 

[SenorNoob]

Congrats! How'd you handle the alignment spacer?

 

[highstakes]

Thank you! This thing was meant to be manual

I didn't.
The starter had almost no movement once the bolts were put in hand tight so I just cranked em down and went with it. No issues so far

Just really puzzled by the softness of my brake pedal. If the pedal is still gross after new fluid and bleeding, what do we think? Bad booster?

 

[SenorNoob]

I would expect a bad booster to cause stiff pedal or a massive vacuum leak.

Sounds to me like there is still air somewhere or That something is pulling the pedal up rather than the fluid pushing it up.

 

[highstakes]

Ok, that's a relief. Hope it gets better after a bleed. At first I was scared a line had cracked but the level of fluid has remained exactly the same for the close to 2 weeks since I got it driving.

Work has been so he hectic i haven't had as much time as I'd like to put the finishing touches on this thing. I should have a good chunk of time on wedsnesday to fix the last couple things