Essay on Aod Cross Member
Aod Cross Member Term Papers
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AOD to T5 swap
1987-93
********THIS IS NOT MY OWN PIECE, BUT IT IS A PIECE THAT I FOUND VERY HELPFUL
Is your AOD giving you trouble? Want to get rid of that sludge box forever? Why don't you do an AOD to T5 swap! Finally, a place where you can get the low down on exactly what it takes to convert from an AOD to a Ford T5 transmission, step by step. First, lets look at what you'll need for the conversion.
Note: The parts listed are for a T5 or T5Z transmission. Swapping to an aftermarket tranny (example: TKO, 3550, T56, etc.) will require a slightly different list of parts. These questions may be answered in the new Q&A list that is under developement.
Things you'll need: Parts
Starter index plate
Bell housing/scatter shield
Pivot ball
T5/T5Z transmission
Shifter
Shifter knob
Shifter weather seal
Shifter boot
Flywheel
Clutch kit (pressure plate, clutch disc, and throw out bearing)
Pilot bearing
Clutch fork
Clutch cable
Clutch cable clip (secures the cable to the bell housing)
Pedal Assembly
Clutch quadrant
Speedometer gear
Back-up light harness (Ford part# E7ZZ-15525-A)
T5 transmission cross member
Exhaust hanger
Bolts:
Upper bell housing bolts (or washers to make up the extra length)
Pressure plate bolts
Starter plate to bell housing bolts
Transmission to bell housing bolts
Tools
Torque wrench
Complete socket set (standard and metric)
Screw drivers (phillips and flat head)
Assortment of wrenches (standard and metric)
12 point, 12mm socket (for the driveshaft)
O2 sensor socket (optional)
Extension(s) approx. 36" long
Jack
Jack stands
Now that you have an idea on the parts and tools needed for the conversion, it's time to brake down the procedure. There are basically 2 parts: Under-the-car and inside-the-car. Under-the-car is the heavy, major conversion work. It's basically the removal of the AOD and the installation of the T5(Z). There is no real "modification" to be done. The only thing that need to be "modified" is the opening for the shifter. The metal is so thin that it can be bent upwards for clearance. The inside-the-car work is basically the installation of the clutch pedal, clutch cable, relocation of the speedometer cable, and removal of the AOD's shifter. Other factoids will be given as the conversion is spelled out. If after going through this you have any questions, please feel free to E-mail me at mailto:black306@aol.com?subject=AOD_to_T5_swap
Inside-the-car
The only reason that I suggest starting with the inside is so that you have room for the shifter when you install the transmission and something to hold on to the clutch fork when installing the T5. This will be more clear as you read the step by step instructions.
Removal of the automatic pedal assembly
Remove the front drivers seat. This will make removing the pedal assembly A LOT easier.
Remove the plastic cover around the steering column and under the dash.
Remove the hood release cable bracket.
Lower the steering column. There are 4 nuts that support the steering column. As you are lowering the column, unplug the wires so that they get taught and support the column.
Remove the nut and bolt from the top of the pedal assembly.
Remove the brake booster rod from the brake pedal.
Remove the 4 nuts on the back of the fire wall (brake booster nuts). The upper left nut is the hardest one to get to. If you look carefully, you can get a ratchet/extension/socket to remove it.
Wiggle the pedal assembly out from under the dash. This is the hardest part. Take your time and try not to get upset. Take a breather or two if you are having trouble.
Relocation of the speedometer cable and install of the clutch cable
Remove the head light switch.
Remove the hazard lights switch.
Remove the gauge cluster cover.
Remove the gauge cluster. There are 2 plugs and the speedometer cable holding it back. Don't force the gauge cluster away from the dash too hard.
Pull the speedometer cable out from under the hood.
Reinstall the speedometer cable through the other hole. If you look directly to the left of where the speedometer cable came out of, you'll see the hole where the speedometer cable needs to go through.
Reinstall the gauge cluster.
Reinstall the gauge cluster cover.
Reinstall the hazard and headlight switches.
Install of the manual pedal assembly
Wiggle the pedal assembly into place.
Reinstall the 4 nuts that go to the brake booster.
Reinstall the nut and bolt on the upper portion of the pedal assembly.
Install the clutch cable though the original hole for the speedometer cable.
Plug the neutral safety switch. The clutch neutral safety switch plugs are already wired in every Mustang. Look under the dash for them. They will be taped up with the main wiring harness.
Reinstall the brake booster rod to the brake pedal.
Raise the steering column and plug the wires associated with the column.
Reinstall the hood release cable bracket.
Reinstall the plastic panels under the dash and around the steering column.
Reinstall the front drivers seat.
Under-the-car
Here is where the work requires muscle. Having a few friends, or calling in a favor, would be a good idea at this point.
Removal of the AOD
Jack up the car as high as you can.
Disconnect the battery
Remove the H-pipe.
Remove the driveshaft. It would be a good idea to plug the tail end of the transmission with another driveshaft...
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