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AOD to 5 speed manual transmission conversion PICS

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AOD to 5 speed manual transmission conversion PICS

  #1  
Old 06-29-2011, 09:06 PM
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AOD to 5 speed manual transmission conversion PICS

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additional photos of tear down on transmission for servicing:

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many more photos to be uploaded. i am not an expert but i made lots of observations and took many pictures along the way
 
  #2  
Old 06-29-2011, 09:12 PM
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  #3  
Old 06-29-2011, 09:18 PM
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  #4  
Old 07-03-2011, 02:03 PM
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Awesome swap man! I wish I had a 4wd manual laying around. i'd love to have a stick shift in my Bronco.

So You swapped the transmission, the cross-member with mount and the starter? What else was required?
 
  #5  
Old 07-03-2011, 02:54 PM
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I do. I'm halfway across the country but I've got two M5's sitting here. Both are 4WD. One needs shift fork assembly. I'm running a ZF and have no use for them.

Nice pictorial there, Dave. Anyone wanting to do a ZF S5-42 swap... have a look at this as well because physically, the ZF and M5 are identical for mountings and hardware.
 
  #6  
Old 07-04-2011, 08:14 PM
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a list of the required pieces when switching from AOD to 5 speed mazda or ZF equivalent:

transmission (obviously)
cross member
cross member gussets or upper rail supports
starter
link bar for manual shift T case to transmission shift mechanism
pedal assembly
master cylinder
slave cylinder
hydraulic line
transmission mount (i am willing to bet they both fit and bolt the same. very minor differences light height)
and most importantly the driveshafts.

the driveshafts are the most important part and i overlooked them. i thought i would be able to use the ones from the AOD for the 5 speed but i was SOL and there was little i could do about it. front shaft from an f150 was perfect but the rear shaft needed a good 2 inches removed from the AOD shaft so i bartered and got mine resized.

as for wiring, snip 2 wires out of the 5 pin plug for the back up lights, and 2 for neutral safety. i chose not to have back up lights so for the other 2 wires just bring them through the firewall directly off the plug on the fender and connect them to the switch on the pedal. it is a "push to be able to start" setup now that easily.

any more info, i have it.
 
  #7  
Old 08-16-2014, 01:40 PM
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1988 bronco

Hey i have a 1988 ford bronco sitting in my garage i just got my liscense and im wanting to put a 5 speed manual transmission in it rather than the stock AOD i pulled my motor and tranny sold my AOD and took my motor down the the block and im rebuilding it at the moment but was wondering what transmission i need that would be easiest to install to my t case and what other parts i would need to swap it properly
 
  #8  
Old 08-16-2014, 07:44 PM
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would this tranny work

Would this transmission work its a m5r2 but its a 1990 SC and it came out of a thunderbird
 
  #9  
Old 04-05-2017, 08:02 PM
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Difference

Originally Posted by fordbroncodave View Post
a list of the required pieces when switching from AOD to 5 speed mazda or ZF equivalent:

transmission (obviously)
cross member
cross member gussets or upper rail supports
starter
link bar for manual shift T case to transmission shift mechanism
pedal assembly
master cylinder
slave cylinder
hydraulic line
transmission mount (i am willing to bet they both fit and bolt the same. very minor differences light height)
and most importantly the driveshafts.

the driveshafts are the most important part and i overlooked them. i thought i would be able to use the ones from the AOD for the 5 speed but i was SOL and there was little i could do about it. front shaft from an f150 was perfect but the rear shaft needed a good 2 inches removed from the AOD shaft so i bartered and got mine resized.

as for wiring, snip 2 wires out of the 5 pin plug for the back up lights, and 2 for neutral safety. i chose not to have back up lights so for the other 2 wires just bring them through the firewall directly off the plug on the fender and connect them to the switch on the pedal. it is a "push to be able to start" setup now that easily.

any more info, i have it.


Driving the truck now with the 5 speed is it better than the aod ?
 
  #10  
Old 10-06-2018, 04:26 PM
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Originally Posted by fordbroncodave View Post
a list of the required pieces when switching from AOD to 5 speed mazda or ZF equivalent:

transmission (obviously)
cross member
cross member gussets or upper rail supports
starter
link bar for manual shift T case to transmission shift mechanism
pedal assembly
master cylinder
slave cylinder
hydraulic line
transmission mount (i am willing to bet they both fit and bolt the same. very minor differences light height)
and most importantly the driveshafts.

the driveshafts are the most important part and i overlooked them. i thought i would be able to use the ones from the AOD for the 5 speed but i was SOL and there was little i could do about it. front shaft from an f150 was perfect but the rear shaft needed a good 2 inches removed from the AOD shaft so i bartered and got mine resized.

as for wiring, snip 2 wires out of the 5 pin plug for the back up lights, and 2 for neutral safety. i chose not to have back up lights so for the other 2 wires just bring them through the firewall directly off the plug on the fender and connect them to the switch on the pedal. it is a "push to be able to start" setup now that easily.

any more info, i have it.
what color are those wires ? I've got it all swapped can't get it to start because I've got two neutral safety switches going on and I dont know what to do about my old auto 5 prong plug.
 
  #11  
Old 10-08-2018, 10:13 AM
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I just swapped from an AOD to a ZF5 as well.

This isn't the best picture, but if you go to the zoomed in view, you can see the wiring colors.





You'll need a plug for a manual transmission. Just connect the reverse light wires to the plug (their order doesn't really matter), and then connect the park/neutral safety switch wires to each other to bypass them.




.
 
  #12  
Old 10-08-2018, 04:46 PM
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Originally Posted by AbandonedBronco View Post
I just swapped from an AOD to a ZF5 as well.

This isn't the best picture, but if you go to the zoomed in view, you can see the wiring colors.





You'll need a plug for a manual transmission. Just connect the reverse light wires to the plug (their order doesn't really matter), and then connect the park/neutral safety switch wires to each other to bypass them.




.
**** fired right up! Now just gotta work on getting clutch to fully engage, I know i got it bleed all the way maybe napa just got me the wrong slave, I used my old fitting off my master that goes into the slave because I couldn't find the male connection for the one new slave anywhere. Maybe I have to adjust my clutch pedal alighnment I dunno.
 
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