How to Replace a AOD with a Ford T5 Transmision
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...
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...t cases, this section of wire can be replaced with a simple 2 wire T5 harness. The 2 wires goto the reverse light switch and the other 2 wires are connected with a jumper wire already on the harness. If you find out there are driveability problems, you may have to also connect the neutral switch on the tranny.
Install the clutch cable cover. Do this now unless you have an aftermarket clutch cable that adjusts on the fork. Adjust the cable first, then put the cover on.
Fill the transmission with ATF fluid. I like doing this at this point since the exhaust isn't in the way yet.
Change the AOD speedometer gear to a T5 speedometer gear. There is a different gear for different differential gear ratios. Consult your SVO supplier for the proper gear.
Install the driveshaft. Torque the bolts to 70-95lbs.
Install the H-pipe.
Install the O2 sensors.
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Measuring the Moment of Inertia of a Flywheel Objective = == == ==