Please clarify - budget driveline improvements on au I6

[BLSTIC]

During my research into boosting my AU I have come across a few interesting bits and pieces. Some will be rumours, others true. Kinda need help separating the wheat from the chaff.

Gearbox:

S5 solenoid: Apparently adjustable in the AU's. Was definately not in my EFII. How is it adjusted and does it have the same effect as intercepting the electronic signal to the S5 solenoid (which I have done in the EFII)?

S3 & S4 solenoids: Listed as shift improvement solenoids (or words to that effect). Rumour has it that disconnecting and emulating these (with resistors) can extend transmission life and reduce slip under the harsh boosted conditions I desire. Can anyone tell me if and why??

Engine:

Conrods:

Rumour has it that the AU and BA rods share the same length and bearing/gudgeon pin sizes, meaning that I can use BA rods in my AU engine.

Confusingly there are 3 different types of rods. Standard rods, turbo rods, and LPG/Typhoon rods. The grouping is strange, but ford press releases did state that the LPG motor has beefed up rods, and FPV releases stated that the 270kw typhoon motors had manlier conrods than the standard XR6t items. The stock, typhoon, and LPG rods appear to be all of similar pricing too...

Pistons:

Apparently AU-BA pistons are interchangeable. I'm having issues believing this, but if true it opens up a whole new avenue of lowering compression for boost. XR6t pistons here I come...

Incedentally, who makes low compression pistons to suit the AU?

Valvetrain:

AU and E-series cams are interchangeable, but only if the rockers and lifters are changed too. How true is this? I find more E-Series cam profiles are available, but there must be a reason ford went to the trouble of changing the system.

Other stuff:

XR6t injectors: Same as standard BA, but run with higher fuel pressure?

Manifold Pressure and Temp sensors: Voltage outputting MAP sensor for ALL AU's? BA sensor direct swap, but 2-Bar scale as opposed to 1-bar?

"Boost Cut": E-Series is 10psi, beyond doubt. Does the AU have one, or does the computer just play dumb and inject enough fuel for WOT throttle without boost?

Also, how hard can these AU engines be revved? They are a lot smoother than the E-series, and have longer rods and lighter pistons, but have the same marked redline. Is the redline there because things will explode above that, or just because higher revs would mean using a wilder cam less suited to the low-rpm range most cars get used in?

Can anyone confirm or deny the above rumours? Every single one of these affects the choices I take along my path to boosted glory.

Thanks
Ben

[russellw]

I'll answer some of this:

Originally Posted by BLSTIC

Gearbox:

S5 solenoid: Apparently adjustable in the AU's. Was definately not in my EFII. How is it adjusted and does it have the same effect as intercepting the electronic signal to the S5 solenoid (which I have done in the EFII)?

S3 & S4 solenoids: Listed as shift improvement solenoids (or words to that effect). Rumour has it that disconnecting and emulating these (with resistors) can extend transmission life and reduce slip under the harsh boosted conditions I desire. Can anyone tell me if and why??

Solenoid S5 is a proportional or variable pressure solenoid that provides the signal pressure to the clutch and band regulator valves thereby controlling shift pressures. .
During a gearshift the PCM. applies a progressively increasing or decreasing (ramped) current to the solenoid. Current applied will vary between a minimum of 0.2 amps and a maximum of 1.275 amps.
Increasing current decreases output (S5) pressure.
Decreasing current increases output (S5) pressure.
Line 500 pressure, 480 kPa, is the reference pressure for the VPS.
S5 output pressure has a maximum value of approximately 450 kPa.

S3 – switches the clutch regulator valve off or on
S1 & S4 – switches the band regulator valve off or on - I'd be struggling to see how either of these could have the impact suggested above although S4 might be able to dampen the valve opening.

Originally Posted by BLSTIC

Engine:

Conrods:
Rumour has it that the AU and BA rods share the same length and bearing/gudgeon pin sizes, meaning that I can use BA rods in my AU engine.

Confusingly there are 3 different types of rods. Standard rods, turbo rods, and LPG/Typhoon rods. The grouping is strange, but ford press releases did state that the LPG motor has beefed up rods, and FPV releases stated that the 270kw typhoon motors had manlier conrods than the standard XR6t items. The stock, typhoon, and LPG rods appear to be all of similar pricing too...

Rods do share the same dimensions between AU and BA. The LPG and Typhoon rods are allegedly stronger to cope with higher combustion chamber loads. If I had to guess I'd think the LPG ones might be the beefier of the two.

Originally Posted by BLSTIC

Pistons:

Apparently AU-BA pistons are interchangeable. I'm having issues believing this, but if true it opens up a whole new avenue of lowering compression for boost. XR6t pistons here I come...

As far as I can tell, they are. The Tech Portal has the dimensions of all engine components for both models so you can compare them but a quick read of the critical measurements shows them to be nearly identical.

Originally Posted by BLSTIC

Valvetrain:

AU and E-series cams are interchangeable, but only if the rockers and lifters are changed too. How true is this? I find more E-Series cam profiles are available, but there must be a reason ford went to the trouble of changing the system.

Possibly true for non VCT engines but it would require a bit more research.

Originally Posted by BLSTIC

XR6t injectors: Same as standard BA, but run with higher fuel pressure?

They list as different part numbers so probably not.

Originally Posted by BLSTIC

Manifold Pressure and Temp sensors: Voltage outputting MAP sensor for ALL AU's? BA sensor direct swap, but 2-Bar scale as opposed to 1-bar?

AU I6's have a T-MAP sensor (refer tech portal for more info on their operation) that are resistance/voltage type output. The AU MAP side has a range of 15-105 kPa which is the same as the BA one except the T-MAP sensor for the turbo which has a range of 10-200 kPa.

Cheers
Russ

[Sox]

Originally Posted by russellw

As far as I can tell, they are. The Tech Portal has the dimensions of all engine components for both models so you can compare them but a quick read of the critical measurements shows them to be nearly identical.

The valve reliefs would be different, 2v VS 4v.

[Papa Smurf]

Originally Posted by BLSTIC

Gearbox:

S5 solenoid: Apparently adjustable in the AU's. Was definately not in my EFII. How is it adjusted and does it have the same effect as intercepting the electronic signal to the S5 solenoid (which I have done in the EFII)?

Solenoid S5 is a proportional or variable pressure solenoid that provides the signal pressure to the
clutch and band regulator valves thereby controlling shift pressures.
A variable pressure solenoid produces an oil pressure inversely proportional to the current applied.
During a gearshift the PCM applies a progressively increasing or decreasing (ramped) current to the
solenoid. Current applied will vary between a minimum of 0.2 amps and a maximum of 1.275 amps.

Increasing current decreases output (S5) pressure. Decreasing current increases output (S5) pressure.
Line 500 pressure, 480 kPa, is the reference pressure for the VPS.
S5 output pressure has a maximum value of approximately 450 kPa.

When the VPS is on standby (i.e. no gearshift is taking place), the VPS current is set at 0.2 amps giving maximum output pressure.
This current may be lower when the lockup clutch is applied in high performance vehicles.

Engine:
Conrods:
Rumor has it that the AU and BA rods share the same length and bearing/gudgeon pin sizes, meaning that I can use BA rods in my AU engine.

AU Con-rods are the same as BA standards and you need to lose all 6 to prevent imbalance

Pistons:
Apparently AU-BA pistons are interchangeable. I'm having issues believing this, but if true it opens up a whole new avenue of lowering compression for boost. XR6t pistons here I come...

Ford lists different pistons and rings.

Other stuff:
XR6t injectors: Same as standard BA, but run with higher fuel pressure?

ALL BA 6cyl injectors are the same and yes the Regulator is different.