Swap A604 to 543 Transmission Problems

[ploppysator]

Hi @all

I just finished installing the 543 and threw the bloody A604 away. I calculated 12 hours, but i used about 40, but finally, the gearbox is in and almost everything is connected. BUT: the car doesn't want to start.

The problems are:

- The P/N wire is chopped of, but i found the place, where i can lift the key out, so it should be in the position, where the car should be able to start. I fixed this wire in this position.

- Almost all electrical stuff works (as soon as the battery has enough power left), also the lights work (i have an european model).

- But: the car doesn't start, the starter is ok, imho everything should be ready, but turning the key (all lights, intended to be on, are all on, as they should) nothing happens .

-> I checked the engine, it turns, so why does it not run/start?

Does anybody know what i should do now?

THX

Bruni

[jory]

The neutral start wire needs to be grounded to start the car, and it needs to be open for cruise to work. It sounds to me like you don't have the wire grounded. On the a604 it would have been on a three wire plug, two outside wires are for the reverse lights and the middle wire is the neutral start switch wire.

quote from my 5-speed swap page:

Quote:

The neutral start switch/reverse light is located on the front right (driver's side) of the transmission. It is a three wire connector, and the wires are BLUE, BROWN/YELLOW*, and PURPLE/LIGHT BLUE*. It has a red grommet. The center wire (BR/Y*) is for the neutral start switch, and it has to be grounded to start the engine, but it has to be open for the cruise control to work. If you don't care about the cruise control you can just wire it to a ground. If you want cruise control to work you will have to make a clutch interlock switch or wire it to a toggle switch. The reverse light wires will have to be spliced into the reverse light switch on the manual transmission, polarity doesn't matter.

Converting a Dodge Spirit to 5-speed

[ploppysator]

Could it be, that the wirings are different on the 1995er, than on the 1994er? I do not find the mentioned wire. The wires look now like this:







My 1994er's wiring looked really different, but i cannot really check, as the car is gone.

Thank U

Bruni

[jory]

You want to look at the connectors that came off the auto transmission. The plugs in those pictures aren't the ones you need to look at. Find the one that has the reverse light wires and the neutral start wire on it.
You can find the wires you need to splice in the right side fender. There will be the TCM with a few relays on it, you should completely remove it.

Just unplug it and pull the transmission sub-harness and modify it to work with the manual transmission. You just need to run 3 wires, the rest of the wires and the TCM are junk. Run the 3 wires to the rectangular plug and call it a day, leave the smaller oval plug dangling, its not needed.



You might have running problems with the stock automatic ECU, having been through it myself I recommend a manual trans computer.
http://memimage.cardomain.com/member...5_373_full.jpg

[ploppysator]

Hi Jory

Thank you for your replies.

Now i removed the TCM and all the wires and this is, what remains:




I connected each of the 6 wires from the white plug to the ground @ the engine and tried to start the engine, but: nothing!

Do you know, where i could get a wiring diagram for the 1995er engine?

bruni

[ploppysator]

Hi Jori, hi all

After removing the TCM and all the plugs, I first had to removed the isolation and i found following mess:




All the plugs except the connection to the TCM look this way:




These are the available plugs:
















I removed all wired, leading to the TCM, to the relais and could separate the 1big black plug and two 3pin plugs:













Obviously the big, black connector is used and not the white one , i suspected, first...There are 3 wires leaving this black plug:

a thick blue one -- leads to 1 side of the 3pin black connector
a thin brown/red one -- leads to the middle of the 3pin grey plug
a thin yellow/brown one -- leads to the the middle of the 3pin black plug

The wires leaving the big rectantular black plug (the ones to the left are chopped off, already):



The 3 pin black plug (only the middle + 1 side wire lead to the grey rectangular plug, the blue and the yellow/browne one (purple one is chopped off)):



The 3 pin grey plug (only the middle brown/red wire is connected to the rectangular black plug, all others are chopped away):



The two 3pin plugs (grey + black):



So, if i understood and checked your comments, i should now do as follows:

- reconnect the black rectangular plug
- as i beleave it is the black plug, you were writing about, i take the blue wire
and the yellow/brown wire
- as the grey one --> please confirm this <-- is not used, i will chop
off the no more used brown/red wire, too

BUT: Where shall i connect the 2 wires, the yellow/brown and the blue one?

There is a 2 pin socket on the A543 (manual transmission) as seen on this picture:



Where shall i connect which wire, does it matter?

Can U please help again?

Thank U a lot

Bruni

[ploppysator]

Hi Jori

You were right , i connected the yellow/brown wire to the ground, this with a screw to where the TCM was fixed, the car runs, i love you !

Now i have the problem with the reverse driving lights, but i am sure, you know, what to do, do you?

Thank you

Ploppy