All Small Six T5 Swap Build Diary

This relates to all small sixes
Nice job. I agree that wrestling the transmission under and up to mate with the engine is the trickiest part and it looks like you came up with a good solution. I llok forward to the reports from your first drives. I did mine over the winter and am working to get it back ont he road over the next couple of weeks.
 
Hey bmbm40 and Andrew,

Thank you both very much. ☺️
I had plenty of time to prepare for the swap, learn from others, and I’ve had enough drama already — enough for two lifetimes. 😉

To be honest, one of the toughest parts for me was removing and reinstalling the starter, mainly because I’m quite small. 🤣 I’m even a bit sore today. 🤣

Now I’m about to get started on the brakes on my other car. 🙈

Cheers,
Chris
A 7 lb. mini starter would make that easier, the auto guys have that option, but the 9'' manual guys do not have that option yet, maybe one day someone will make one.
 
Nice job. I agree that wrestling the transmission under and up to mate with the engine is the trickiest part and it looks like you came up with a good solution. I llok forward to the reports from your first drives. I did mine over the winter and am working to get it back ont he road over the next couple of weeks.
Hey Motopycha,

Thank you so much, I’m really glad everything worked out so well. I hope yours will be back on the road soon so you can drive it again. I absolutely love the feeling in that car — time somehow moves differently, and people are always smiling. 😅

I still love thinking back to when I picked it up. I drove 600 km on its own wheels, the radiator was completely clogged with scale and there was dirt in the engine. I was driving at around 38 mph, going from parking spot to parking spot just to let it cool down again. That was a hot ride with the horse 😅 Luckily nothing happened, but I preferred to be a bit cautious. Back then it took me 12 hours for the 600 km. My butt didn’t even hurt, and the reactions from people on the highway were incredible. 🤣

The next day I immediately ordered a new 3-row aluminum radiator and a heater core, flushed the engine thoroughly a few times, and installed a filter in the hose. Since then, thankfully, I haven’t had any problems.

A 7 lb. mini starter would make that easier, the auto guys have that option, but the 9'' manual guys do not have that option yet, maybe one day someone will make one.
Hey drag-200stang,

I’m not entirely sure, but the mini starter works with the 8.5” (or 132) as well, right? Either way, if someone ever makes a mini starter for our 9-inch, I’m ordering one immediately. 😅





Today I didn’t feel like crawling under the car again. I still need to check the handbrake — I think the adjuster isn’t working properly. Once that’s sorted, I’ll take it out for its first drive. 😅

Cheers
Chris
 
Today I didn’t feel like crawling under the car again. I still need to check the handbrake — I think the adjuster isn’t working properly. Once that’s sorted, I’ll take it out for its first drive. 😅

Yes, the handbrake will need some adjustment if you upgraded the transmission x-member. Mine was never too swift to begin with but after I redid the brakes and adjusted it, it seems adequate. If I'm parked on a hill I always leave it in gear as a safety precaution.

My method for applying the hand brake is to have the brakes engaged via the foot brake and then pull the handbrake on. That way you're not just depending on arm strength and the cable.
 
Hey Motopycha,

Thank you so much, I’m really glad everything worked out so well. I hope yours will be back on the road soon so you can drive it again. I absolutely love the feeling in that car — time somehow moves differently, and people are always smiling. 😅

I still love thinking back to when I picked it up. I drove 600 km on its own wheels, the radiator was completely clogged with scale and there was dirt in the engine. I was driving at around 38 mph, going from parking spot to parking spot just to let it cool down again. That was a hot ride with the horse 😅 Luckily nothing happened, but I preferred to be a bit cautious. Back then it took me 12 hours for the 600 km. My butt didn’t even hurt, and the reactions from people on the highway were incredible. 🤣

The next day I immediately ordered a new 3-row aluminum radiator and a heater core, flushed the engine thoroughly a few times, and installed a filter in the hose. Since then, thankfully, I haven’t had any problems.


Hey drag-200stang,

I’m not entirely sure, but the mini starter works with the 8.5” (or 132) as well, right? Either way, if someone ever makes a mini starter for our 9-inch, I’m ordering one immediately. 😅





Today I didn’t feel like crawling under the car again. I still need to check the handbrake — I think the adjuster isn’t working properly. Once that’s sorted, I’ll take it out for its first drive. 😅

Cheers
Chris
HAHA good story about getting it home sounds like you were fortunate to make it. And yeah driving a classic is an experience at least to me and you will see how good it can be with the T5. The T5 is a performance modification on it's own and a huge drivability upgrade as many have stated previously. Mine is not an identical experience but in about 2009 when I went from the old 3 speed tractor transmission in my Bronco to the NV3550 5 speed od the transformation was huge. Just being able to cruise comfortably with a little less racket at 65 made it feel like a different vehicle and made it much more useable. For full disclosure at the same time I did move up from the 200 to the 250 for the NV3550 to work out so a substantial torque increase also added to the experience.
 
Hey drag-200stang,

I’m not entirely sure, but the mini starter works with the 8.5” (or 132) as well, right? Either way, if someone ever makes a mini starter for our 9-inch, I’m ordering one immediately. 😅
I am not sure about the 8.5 flywheel but I know that the auto is doable, I am sure someone here knows.
 
HAHA good story about getting it home sounds like you were fortunate to make it. And yeah driving a classic is an experience at least to me and you will see how good it can be with the T5. The T5 is a performance modification on it's own and a huge drivability upgrade as many have stated previously. Mine is not an identical experience but in about 2009 when I went from the old 3 speed tractor transmission in my Bronco to the NV3550 5 speed od the transformation was huge. Just being able to cruise comfortably with a little less racket at 65 made it feel like a different vehicle and made it much more useable. For full disclosure at the same time I did move up from the 200 to the 250 for the NV3550 to work out so a substantial torque increase also added to the experience.
Yeah, I’m also really glad nothing serious happened. Back then the seller obviously never mentioned that the car had problems — he only said that he didn’t like the transmission and that he had already had it repaired once. 🙈 But luckily it won’t be needed anymore now. 😁

🔥 Oh, a Bronco — also a very beautiful vehicle! What year is it?

A 250 would have been cool as well. I actually had one once, but unfortunately it doesn’t fit into a ’66 without some modifications, which is why I only kept the head and got rid of the rest.

Right now I’m thinking about possibly swapping the rear end to an 8-inch. That’s going to become its own project again because I want to build everything exactly the way I want it, with custom axles and so on. The hardest part is actually finding someone willing to ship the housing overseas, so we’ll probably be talking about this again next year. 🤣
 
Yeah, I’m also really glad nothing serious happened. Back then the seller obviously never mentioned that the car had problems — he only said that he didn’t like the transmission and that he had already had it repaired once. 🙈 But luckily it won’t be needed anymore now. 😁

🔥 Oh, a Bronco — also a very beautiful vehicle! What year is it?

A 250 would have been cool as well. I actually had one once, but unfortunately it doesn’t fit into a ’66 without some modifications, which is why I only kept the head and got rid of the rest.

Right now I’m thinking about possibly swapping the rear end to an 8-inch. That’s going to become its own project again because I want to build everything exactly the way I want it, with custom axles and so on. The hardest part is actually finding someone willing to ship the housing overseas, so we’ll probably be talking about this again next year. 🤣
1966 Bronco originally a 170 then a 200 and now 250.

The 8" could be very useful when you get your 200 hopped-up and if you will be driving enthusiastically. I learned with my Bronco mods the best time to start looking for parts for these old vehicles is now.

You may have started considering suspension upgrades and I have attached a document our good friend Bubba22349 provided which discusses overall improvements for early Mustangs and has some good suspension upgrade suggestions.
 

Attachments

1966 Bronco originally a 170 then a 200 and now 250.

The 8" could be very useful when you get your 200 hopped-up and if you will be driving enthusiastically. I learned with my Bronco mods the best time to start looking for parts for these old vehicles is now.

You may have started considering suspension upgrades and I have attached a document our good friend Bubba22349 provided which discusses overall improvements for early Mustangs and has some good suspension upgrade suggestions.
Hello bmbm40,

Thank you very much for the document from bubba22349. He had incredible knowledge and was always willing to help everyone. I still truly enjoy reading his posts today. 😢
I took your advice to heart and today I bought an 8-inch rear end housing from a ’72 Comet. 🙈 It will probably not be delivered until autumn, but for now it was important to secure the housing first. Everything else will be bought step by step afterwards, and I will most likely order the axles from Dutchman. 😊

Hello everyone,

After taking a day off, I finally managed to continue working on my Mustang again. Today I first adjusted the handbrake, and now it works properly again. 👌
After that, I used a Dremel with a cutting disc to enlarge the tunnel opening by a few millimeters on the right side. @awasson, you were right — the metal in that area is unbelievably hard. Afterwards, I deburred and sealed the cut edge, then slid the original shifter boot onto the shifter and reassembled everything.

Then it was finally time for the very first test drive. 🤠 Wow — it really feels like a completely different car now. The clutch still feels a bit unusual, but it disengages cleanly. Taking off is much more relaxed than before — no more revving the engine sky-high. Now I can simply pull away normally without people thinking I’m about to do a burnout, only to crawl away slowly afterwards. 🤣 Tomorrow there’s a small meet-up here in the area, and I’m going to drive there. 😊

Cheers,
Chris
 

Attachments

  • IMG_6083.jpeg
    IMG_6083.jpeg
    2 MB · Views: 4
  • IMG_6084.jpeg
    IMG_6084.jpeg
    2.6 MB · Views: 4
  • IMG_6089.jpeg
    IMG_6089.jpeg
    1.2 MB · Views: 4
  • IMG_6090.jpeg
    IMG_6090.jpeg
    3.3 MB · Views: 4
Congratulations!! That’s awesome! I’ve had mine for a year now and every time I drive it, I’m just stunned with how it has transformed the car.

Today I had to drive 40km to a tool rental place to rent a pin finder metal detector so I can figure out where my water main was buried by the contractors owning built my neighbor’s house. Any excuse to go for a drive. On the way there traffic was a brisk 70MPH and sometimes up to 80MPH. I was pulling about 2200 RPM at 70 MPH and about 2500 RPM at 80 MPH. I need to have my driveshaft balance (or replaced with an aluminum one from a Ford Explorer) but aside from that, my car is very happy at those speeds. On the way back, I hit a lot of slow traffic exiting and entering the highway as I headed through metro Vancouver and over to the North Shore. I went from 70 MPH in 5th to crawling along in 1st and 2nd gear but again, it’s so well geared my car just takes it in its stride.

Have a great meet up tomorrow and again, congratulations on a job well done!
 
I have heard- don’t know for sure- that the drive shaft and rear end junction needs to be clocked. If you are getting a vibration, remove the shaft from the differential, rotate it 180 degrees and reinstall. It might help 👍
 
I have heard- don’t know for sure- that the drive shaft and rear end junction needs to be clocked. If you are getting a vibration, remove the shaft from the differential, rotate it 180 degrees and reinstall. It might help 👍

Thanks for the tip. I will definitely give that a try.
 
Back
Top