How to swap in a manaul T5 transmission

[sleeper_inc]

Ok guys, after my A4LD took a **** on me, I decided I'd go manual... I bought my T5 from a tow yard for $250 with everything that I wanted off the car. So here's the specs on the T5 Rebuilt less than 30,000kms ago (around 18,000 miles) has 3.97 1st gear... other wise stock I had the flywheel re-surfaced for $50 and trust me, you should all get it done by a shop and not by yourself... It turns out so much better. Bought a stock replacement clutch kit for a 1988 Mustang 2.3 with an ungraded pressure plate (has 8 extra fingers compared to stock) Also to give you some helpfull tips, a 2.3 N/A flywheel is made for a 8.5" clutch, SVO flywheel is made for a 8.75" clutch, Merkur flywheel is made for a 9" clutch and the Turbo coupes flywheel is made for 9.25" clutch. a flywheel made for a 8.5" clutch wont work with a 8.75" clutch, and a 9" wont work with a 9.25" clutch soTHEY DO NOT INTERCHANGE! I'm running a 8.5" clutch and it's holding the power good, but if you're going to have loads of power than I would tell you to grab a TC flywheel and run a 9.25" clutch or a 5.0 clutch with some mods. This swap will work with almost any fox body ford, you may have to change a few things but it should still follow the same principle. Cost Transmission $250 Fly wheel resurfacing $50 Clutch kit $200 Transmission fluid $15 This is what your shifter should look like Remove the robber outlining, this can be thrown away or used to throw at someone who's in your way Remove the plastic covering around the shifter to get at the bolts 4 8mm bolts holding the gear indicator in place. I removed mine (see below) to get better access to the bolts This is a connection for your light to show you your gear at night... Also there are 2 bolts you'll have to remove here And here You'll have to use a 8mm wrench to get the bolts out from under the dash You'll then have to disconnect the shifter linkage with a 13mm wrench to remove the shifter It'll take some time but you can get the whole shifter housing out without taking the consul out Next remove your exhaust, raise your car and support it properly Use a block of wood between the transmission and the jack so you don't punch a hole in it causing transmission fluid to pour all over you Next remove your driveshaft. If you don't not have a impact like I did, use a screw driver to keep the pinion from turning on you (id did this as well and yes it dose work Auto and manual driveshaft comparison... Do you see why the auto one on the 2.3 wont work now?? Make sure to bag and tag all your bolts or else you'll lose them (I stopped and lost 3 bolts... damnit!) Next is the speedometer and VSS connection on the transmission

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[sleeper_inc]

Remove the VSS/speedometer gear with a 10mm wrench


It's out!!


This is the CCL switch on the A4LD's. Driverside just behind the bellhousing


This is the only 17mm bolt that has to be removed, the rest that hold the transmission to the engine are 13mm


3 bots holding the starter


Disconnected the battery, and the transmission fluid lines (make sure to have a drain pan underneath (13mm or 12mm)


Cut transmission lines


Auto crossmember held in by the mounts on the frame, and the mounts are held on by one bolt and nut each


Starter removed, and you can see the converter bolts which are 15mm. Use a wrench and a long pole to keep the engine from turning over when you remove the converter bolts


Remove the kick down cable


Remove the crossmember, WHILE THE TRANSMISSION IS SUPPORTED by the jack and pull the transmission out. This transmission is full of FAILURE!


With the auto out, remove the flex plate remembering to have the engine locked down with a wrench and a pole. Use a breaker bar or a torque qrench to remove the bolts (15mm)


Now you can see if the seal is leaking, mine was (as you can see) so I replaced with the pictures below


Use a flat head and a hammer to get into the seal and pry it out


seal coming out



Old seal on the left and new on the right


seals out


Lube the new seal with motor oil so it wont tare on first fire up and installs easier

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Oil seal ready to be pushed in


Using a hammer to drive the seal into place


Use thread locker on the fly wheel bolts to stop them from backing out on you... This thing weighs 20lbs after getting it resurfaced


Manual bolt on to, auto on the bottom... You see why you need to grab them before you do the swap?


Dirty fly wheel installed


Torquing the fly wheel down to 85ft lbs (I don't want this bitch to get lose!)


There is a o-ring seal you want pointing towards the transmission


Time to clean the fly wheel with acetone to get all the grease and oil off the fly wheel so the clutch wont slip


ooooooo clean fly wheel


Use a long socket and a hammer to knock the pilot bearing into position


See the alignment tool? USE IT!


Not so hard? was it


This is what you use the alignment tool for... It saves you alot of time and headache



Pressure plate installed with the bolts torqued to 40ft lbs


Lube the splines on the clutch with the supplied lube


New throw out bearing installed

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Shifter in it's place


Modded auto crossmember


Added 2 holes and spacers, works perfect



Modded return line, works fine




Remove all the covering to get to the bracing


Remove this so you can drop the steering column and remove the pedals easier



Remove the connections on the column to make removal easier



Remove the bolts on the column supports to remove the hood release and drop the column down



Removing the seat makes this swap a TON easier



All the connections removed and steering column ready to be removed


Remove this bolt and pull the steering column if you want it removed, I kept mine in because my bolt was seized on


These two bolts (and the ones below) hold the brake booster in place, they must be removed (15mm)


Remove

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Remove


Use a long extension to get at the bolts




Bolts removed, ready for the booster to be pulled forward



Use the crow bar to forced the brake booster forward to pull the studs forward




Remove the BSS(?) and the brake light switch, they should slide right off after the lock pin is removed


More bolts on top (ohhh goody)


This big bolt is a PITA to remove



Pedals ready to be removed



Auto Vs. Manual pedals



The white outlines need to be cut out to make it fit easier


Remove the vacuum tree


Where the speedometer cable goes through the fire wall is where the clutch cable goes through.

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Left - speedometer cable through the fire wall
right - clutch cable almost installed, just need to put a bolt in that hole


These cables are in the auto cars right at the back of the fire wall near the wiring harness. These are the clutch safty switch


They go here

The rest is reverse. The only thing that you would need to do differently is the mounting location of the speedometer cable and the clutch cable.

If you use the auto crossmember then you'll have to drill 2 new holes and use spacers since its going to have to be used in the manual location because it has to be moved back. The manual mounts are wider than the auto mounts, hence the spacers.

[mg man 75]

Awesome Sleeper. Didn't know differant in TC setup. If know it could have got one of these setup this weekend. I didn't need it so didn't both. Cluch pedals bellhousing everything there. Learn something everyday.

[Stang2.3]

SICK!!! Sounds like you had a blast

[sleeper_inc]

Your welcome guys, I had issues finding a good how to so I got as many pictures as I thought it would need

Also the mustang has no grip in 1st at all... It's a whole new animal now

[Stang2.3]

Manuals are a whole lot more fun! can't launch a Auto like you can a Manual (at least stock for stock lol)