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  1. #26

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    Got the 302 pulled out of the donor car this weekend! We also removed the front sway bar while we were at it. The Zephyr is sitting in the carport while we prep the 2.3 for removal.





    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  2. #27

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    More progress got the 2.3 out of the Zephyr today









    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  3. #28

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    Dropped the 302 in! The Stifflers transmission crossmember lined up with the AOD and the stock mount. Also cut the hole for the floor shifter and installed the front sway bar from the convertible. We had to drill the k member for the dowels on the new convertible motor mounts, but other than that it was pretty straightforward.













    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  4. #29

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    It's been chilly here the past couple of days so I got some work done on the inside of the Zephyr. I got the floor shifter installed and removed the column shifter and shift tube from the column. At some point we'll make a surround for the floor shifter probably out of wood.



    I was able to find a rare shift indicator delete panel at the junkyard for Fairmonts/Zephyrs ordered with a floor shifter and standard gauges. This one is from a 1980 Fairmont, but most people won't notice the difference!


    I found these floor shift column covers at the same junk yard, but they came from a 1979 Fairmont with a 6 cylinder and a 4 speed


    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  5. #30

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    Did you swap out the eb wiring harness from the mustang?

    How long before you start it up?

    This is a fun build you've got going here, keep up the work, you're doing great.

  6. #31

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    Looking great! You can probably spiff up that gear selector cover thingy pretty easily with some paint markers. I love the original interior color you have. Hopefully you can find a paint/dye that decently duplicates it.
    Brad

    '79 Mercury Zephyr ES 5.0L GT40 EFI T-5 (Mustang LWB)
    '17 Ford Transit Connect Titanium LWB
    '14 Ford Fusion SE Manual

  7. #32
    FEP Member Dave9052's Avatar
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    Very nice!! Looking sharp!!

  8. #33

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    Quote Originally Posted by Davedacarpainter View Post
    Did you swap out the eb wiring harness from the mustang?

    How long before you start it up?

    This is a fun build you've got going here, keep up the work, you're doing great.
    I didn't swap the harness it's staying carbureted. I have an Edelbrock Performer 289 intake and an Edelbrock 600 cfm carb for it. I also have a 1985 Mustang distributor. I'm hoping to get it running before winter, but we'll see! Thanks!

    Quote Originally Posted by ZephyrEFI View Post
    Looking great! You can probably spiff up that gear selector cover thingy pretty easily with some paint markers. I love the original interior color you have. Hopefully you can find a paint/dye that decently duplicates it.
    Thanks! Yea, I plan to touch it up along with the outside emblems with a silver sharpie. The closest dye I've found is Duplicolor's tan interior dye. It matches most of the interior except the dash.

    Quote Originally Posted by Dave9052 View Post
    Very nice!! Looking sharp!!
    Thanks!
    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  9. #34

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    I started out by swapping the white connector Duraspark box for a blue one and it looks like all I have to change in the wiring is lengthening the 3 wires that go to the distributor. I still need to check the length on the gauge sender wires also.

    Pulled the efi intake and bolted on the Edelbrock intake. Some chrome Edelbrock valve covers are gonna go on too to keep pcv.





    Underneath, I hooked up the speedo cable, shifter cable, and transmission wiring. I was able to use the speedometer cable and transmission harness from the Zephyr since the C3 used the same neutral safety switch as the AOD. The only thing left to deal with transmission wise is hooking up the TV cable to the carb linkage. I have a TCI 376710 TV cable corrector for an Edelbrock carb, but I'm gonna have to figure out a way to attach the factory TV cable to it.



    For anyone concerned with how close the stifflers crossmember is to the trans pan there's plenty of clearance.
    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  10. #35

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    Today's motor swap progress. You can't see much got done, but it did.

    bolted the trans crossmember up

    tightened the trans cooler lines to the transmission

    installed the v8 throttle cable

    wired up the alternator

    dropped the distributor in and wired it up

    attached the power steering hoses

    hooked the starter wire up to the solenoid

    pressed the u joints out of the Explorer and Mustang driveshafts







    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  11. #36

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    Looks like good progress is made! As far as ignition, it looks like you have it covered, but if you don't want to wire up the duraspark there's an easy way. Get a cheap MSD box like a street fire and you can make or buy a harness that runs from the distributor plug to the magnetic input of the MSD. If you buy the MSD harness and it runs like crap at first, unpin and reverse the 2 wires. Mine were backwards.
    1985 GT, Sunroof, 5 Lug, Rear Discs, 01 Graphite Bullets, 88 forged piston shortblock, 2.02/1.60 Alum heads, Weiand Stealth, Holley C950 TBI, BBK Long tubes

  12. #37

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    Today's update!

    I ran into a snag with the Explorer driveshaft. I used the 1-0134dl (353) u joint to put the yokes from the Mustang on the Explorer driveshaft, and it went together fine, but the driveshaft is hitting the dampener ring on the slip yoke. Has anyone run into this before? The driveshaft is from a 1996 Explorer V6 4 door 2wd and the yokes are from a 1989 Mustang 5.0 AOD. Am I supposed to remove the dampener ring from the yoke?







    I also got the Valve covers on and the Carburetor on.













    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  13. #38
    FEP Supporter 4-barrel Mike's Avatar
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    Yes, remove the ring.



    Mike
    1985 ascMcLaren 5.0 SC Roadster
    My '78 Fairmont build - http://vb.foureyedpride.com/showthre...539-78-Big-Red

  14. #39

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    Yep, my dampener ring is gone too. I used the F/Z yokes and hybrid u-joints.

    Sent from my XT1650 using Tapatalk
    Brad

    '79 Mercury Zephyr ES 5.0L GT40 EFI T-5 (Mustang LWB)
    '17 Ford Transit Connect Titanium LWB
    '14 Ford Fusion SE Manual

  15. #40

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    Thanks, I'll try to get it back apart this week and press the ring off. I might grind the notches in the yoke a little deeper too for clearance.
    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  16. #41

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    Finished up the driveshaft today and worked on the exhaust. We pressed the dampener ring off the slip yoke, and that gave enough clearance with the rear axle hanging. I didn't have to grind out the u joint reliefs in the yoke. Got the Mac h pipe installed and hung the tail pipes using the Mustang hangers.









    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  17. #42

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    Fabbed up the throttle cable bracket today. It's not the prettiest, but it does the job. I used a TCI throttle tv corrector and the modified stock 86-93 Mustang tv cable. The throttle cable is a stock replacement for an 85 Mustang GT 5 speed. The TCI throttle adapter comes with a clip on throttle stud for the carb. The Mustang throttle cable uses a ball stud so I bought the extra long stud throttle ball from Jegs part # 555-15226.

    The tv cable hookup is a clip on too so I just removed the plastic adjuster from the cable and looped the cable around the hookup and used a 3/16 crimp clamp to make the loop. Then I put on an e clip to hold it in place.















    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  18. #43

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    It's almost ready to start up. Pretty much all that's left now is finishing the exhaust and changing the oil and transmission fluid. I'm gonna go with turbo mufflers because they're on the quieter side for a sleeper.











    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  19. #44

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    The Zephyr is running now! We took it to dinner tonight. I had some issues with the distributor cap adapter moving because the clips that hold it down were too loose and it was letting the rotor hit the cap. And I had to do some adjusting on the tv cable to get the trans shifting correctly, but other than that so far so good.

    The immediate next thing is making a trim surround for the shifter, giving it a bath, and getting the mufflers installed correctly.

    Then when it get warm weather again we'll install the 87+ front brakes. We already have the spindles and calipers.

    After that we can paint it.





    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  20. #45
    FEP Supporter 4-barrel Mike's Avatar
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    Well done.

    Mike
    1985 ascMcLaren 5.0 SC Roadster
    My '78 Fairmont build - http://vb.foureyedpride.com/showthre...539-78-Big-Red

  21. #46

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    That's awesome, great job!
    Brad

    '79 Mercury Zephyr ES 5.0L GT40 EFI T-5 (Mustang LWB)
    '17 Ford Transit Connect Titanium LWB
    '14 Ford Fusion SE Manual

  22. #47

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    Started on the paint today! Nothing fancy just a basic scuff and spray.



    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

  23. #48

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    Nice build! My grand parents had a wagon with a 5.0 and AOD in it... I think from the factory. For the time could pass about anything but a gas pump. Classic ford carb that dumps too much fuel.

  24. #49

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    I like this car. I’m sure is every bit as underestimated as my rusted out old 86 GT Mustang. Should run great with that intake and carb. Nice work on the brackets.

  25. #50

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    Started sanding the sides yesterday







    Matt
    1980 Mercury Zephyr 4 door sleeper. Was a 2.3 4cyl, now with a 302 HO, AOD, and 8.8" axle from a wrecked 89 Mustang. Edelbrock Performer 289 intake, Edelbrock 600 cfm carb, Mac o/r h pipe, Thrush turbo mufflers, 2004 Mustang bucket seats, Grant steering wheel, and 89 Mustang 5.0 front and rear sway bars.

    1988 Mustang GT hatch -- Explorer intake, GT40 heads with Trick Flow spring kit, Crane 1.7 rrs, 70mm MAF, 70mm throttle body, Kirban Kwik shifter w/ Pro 5.0 Deluxe handle, clutch quadrant and firewall adjuster, and 3.27s
    1986 Mercury Cougar 5.0 (sold), 1989 Lincoln Mark VII LSC 5.0 5 speed (sold)

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