Well, Saturday was the day. I had everything gathered up and ready to roll.

Thanks first to fordka for supplying the pedal assy and the crossmember. Good guy to deal with.

I hung the pedals a month or so ago to get started with the deal. I then got it on the lift Saturday morning about 8am and went to work. Got the AOD out and the clutch/5spd in the truck by 11:30am. All was going well, as figured. Took a lunch break and continued about 2:30.

The big step for getting the transmission in the truck was getting a hole in the floor for the shifter. I had the removable panel from a parts truck, but my floor was not molded for cutting it to fit(and I didn't want to get into all that if I didn't have to). I just measured and used a holesaw to put a 4 1/2" hole in the correct spot. Worked great, but had to put a 2" slot backwards to allow the transmission shifter pole to stick up through the floor to get it onto the engine(even after dropping engine down in the back as far as I could). I then pushed the flap back down.

The next step was getting the stock boot to fit. Again since my floor was not flat I cut the ridge off the boot molding and then just pulled it down with 4 screws. It is not completely flat with carpet, but close enough and looks pretty stock.

I installed the master cylinder and line to slave. Took about 1/2 hr to get it all bled and functioning properly. Kinda a bitch, but once you get fluid moving it was okay and pumped up fine.

It was just about 6pm when I got it off the lift and drove it out. Took a few hours longer then expected, but not a big deal. I knew the clutch bleeding would be a time consuming job(never did one before and read online how others did them). If it would have been a mechanical linkage it would have been a no brainer.

I do notice the OD in the 5spd(.79) is not the same as the AOD(.67 od). Runs a few hundred RPM higher on the highway. The 5spd has quite a deep first(deeper then I remember). I know they aren't really a creeper first, but darn near like a ZF.

I had to convert mine from a '92-up into a 91-older with mechanical speedo. It worked out okay, but the clip I was given didn't quite hold the gear and it popped loose and slid back on the shaft making the speedo non functional. I guess I need to pull tailhousing and fix that someday.

 

I continue to use a wire instead of that clip it seems to work fine

 

For the speedo gear?

I machined the shaft(dimpled it) to accept the clip pin, which I don't recall exactly what transmission it was for? I then had to cut a groove through the ID of the gear to allow it to slide over the clip.

My friend jumped the gun and glued the tailhousing on before I could recheck to make sure the clip was secure. I just forgot about it til it quickly quit working. Ugh.

 

I meant the other gear I thought that's the one you meant

 

It's the gear inside the transmission, not the driven gear on the cable. Unfortunately.

I should have just machined the shaft for a snap ring instead of that stupid clip. Ugh, bad decision.

 

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