FREE ESSAY ON AOD CROSS MEMBER

AOD CROSS MEMBER

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 yoke to prevent fluid spillage. 
Remove the inspection plate in front of the transmission. 
Unbolt the torque converter from the flex plate. Use a socket/extension/ratchet on the
harmonic balancer bolt to help turn the motor to get to the other nuts. 
Remove the starter. 
Disconnect the TV (Throttle Valve; cable to the throttle body) and shifter cable. Make
sure that you also remove their respective cable brackets. 
Remove the transmission cooler lines. If you dont plan to ever put an AOD back in, hack
away. 
Remove the transmission cross member. Make sure you have the floor jack supporting the
transmission before removing the cross member. 
Remove the upper transmission bolts. Lowering the floor jack to allow the
engine/transmission to tip back will give you access to the top bell housing bolts
easily. Use the 36 long extension to help with removal.
Raise the transmission back up. Before taking out the lower bolts, raise the transmission
so that it doesn't slide from the jack. 
Remove the lower transmission bolts. 
Lower the transmission. You'll have to shake the transmission a bit and pull backwards to
get it away from the engine. 
Slide the transmission out from under the car. Unless you have really tall jacks, you'll
have to raise the rear of the transmission to clear the floor pan of the car. Bolt the
inspection plate back on the transmission to prevent the torque converter from falling
out and spilling transmission fluid everywhere. 
Rear Main Seal (optional) 
There you have it. The AOD is now out of your car. Before installing the T5, now would be
a good time to change the rear main seal. Many 5.0's are plagued with the rear main seal
leaking. Great time to kill two birds with one stone. All it takes is a flat head screw
driver and a hammer to pop it out. Just make sure you done nick the crank. Hit the screw
driver slowly. 
When installing the rear main seal, just use a blunt object and hammer to tap it in. Make
sure you go around evenly as to not warp the seal and cause it to leak. 
AOD Shifter Removal 
Now that you have room under the car, undo the cable to the shifter. After you have done
this, its a matter of unscrewing the 4 bolts inside the car to remove the shifter. The
hole in the center console is a bit tight for the shifter. The console will flex a bit,
but if you are careful you can remove the shifter without removing the console. After
pulling out the shifter, you'll need to make more room for the T5(Z)'s shifter. The front
part of the opening in the floor pan can be hammered up or you can cut about 1/2 more
length for the hole. 
Install of the T5(Z) 
Install the pilot bearing. Don't strike the pilot bearing with a hammer directly. Place
an over sized socket on the pilot bearing and hit the socket. 
Place the starter index plate on the back of the block. To help hold the starter plate,
use a couple bellhousing bolts to secure the plate to the block while you install the
flywheel and clutch. 
Install the flywheel. You can use the AOD's flexplate bolts for this. Torque them down to
75-85lbs. 
Place clutch on the flywheel. Use a clutch alignment tool to hold the disc onto the
flywheel.
Bolt the pressure plate to the flywheel. Torque the pressure plate bolt to 12-24lbs. 
Remove the clutch alignment tool. I know it seems stupid to put this step but I knew a
person that didn't reinstall a radiator cap cause it didn't say so on the back of the
bottle!! 
Install the bell housing. Torque the bolts to 39-54lbs. 
Place the clutch fork in the bell housing. This can be done by routing the fork from the
rear opening towards the side opening on the bel housing. 
Install the throwout bearing. I find it easier to place the fork in the bell housing
first, then install the bearing. 
Install the clutch cable. Having the clutch cable hold the fork makes it easier to
install the tranny. 
Bolt the tranny to the bellhousing. Make sure that the shifter is already installed but
not the handle. Having the handle installed just make it harder to install the tranny
cause it can hit the floor pan of the car. Torque the bolts to 36-50lbs. 
Install the cross member and exhaust hanger. AOD cross member and exhaust hanger are
different. You might be able to get away with grinding the cross member, but the exhaust
hanger will interfere with the VSS on the T5. 
Change the AOD's neutral safety switch to a T5(Z)'s reverse light switch. The AOD's
wiring harness for this consist of 4 wires. In most 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.