Do the TKO swap myself, or pay to have it done?

Soon enough I will be upgrading from a stock T-5 to a TKO500 with a new clutch. I have never done a tranny or clutch swap before so I do not know how involved it is. However, I have done a complete H/I/C swap all by myself before, so I am somewhat mechanically inclined. I have a friend who has swapped a new T-5/clutch into a fox body before, but never a TKO. He is willing to help me. Should I be okay to do the swap myself with the help of my friend, or would it be smarter to pay a very reputable tranny shop to do the work? How involved is it? I have plenty of jacks and tools to do the job, but I still feel a bit nervous about attempting the swap myself incase something goes wrong. What should I do? :shrug:
 
Depends on the price. It depends on weather it's worth the headaches to you or not. First time, doing as much as you plan to do, on your back on jackstands, it's going to be a migrain at times. Air tools including a 1/2" impact will make a world of difference.
 
90mustangGT said:
Depends on the price. It depends on weather it's worth the headaches to you or not. First time, doing as much as you plan to do, on your back on jackstands, it's going to be a migrain at times. Air tools including a 1/2" impact will make a world of difference.

Like I said, I am all set when it comes to tools. My friend has a complete air tool set.

A very reputable tranny shop estimated me anywhere from $300-$500 to install it.
 
I'll be honest, last summer when I bought my tko, scattershield and clutch I took it to a dude to put in for me. It was a guy that my friends have used, not just some random corner gas station mechanic. He charged me $300 and got the car back to me in 6 hours. That included resurfacing the flywheel. I brought him all the necessary parts including fluid, pilot bearing, rear main, clutch, scattershield and speedo gear. If you have a longtube header then the scattershield will be a bitch to install especially on your back.

Now when I put my 347 in, I put the engine and trans in as one. That I did myself and I had my friend help me guide it in.

Sometimes its just easier to pay someone and have it done quickly than dick around and end up with a headache. The $300 i paid was fair IMO considering I had the car back that day 6 hours later.
 
Labor time: by yourself, first time - 4-6 hours from the time the car gets up on jackstands until the trans sits on the ground & the bellhousing is off. You'll have about the same amount of time to get it reassembled & back in service.

You need both metric & US tools to do the job, the body bolts are metric & the trans mount & engine bolts are US.

The rear driveshaft bolts are 12MM, 12 point and require a first class box end wrench (ring spanner if you are English or Canadian) to remove them. Don't get cheap here or you will regret it. I set the emergency brake and apply a foot to loosen the bolts. Notice the paint marks on the driveshaft & rear end flange: align them the same way they came off. If there aren't any marks, get out your paint spray can & make your own marks.

Be sure to drain the fluid before you remove the trans or you will get to wear it. The best time to do this is before you remove the driveshaft. Have a catch pan in place to get the fluid that comes out of the trans when you pull the driveshaft yoke out. T5's take a good grade of ATF, Tremec 3550 & TKO use 2 3/4 quarts GM Syncromesh at $9+ a quart.

The speedo cable pulls straight out of the adapter, don't pull the clip out of the adapter. It re-installs the same way: push hard on the cable. You can unbolt the speedo cable adapter and pull it out of the trans: this may be the easiest way. Then you don't have to worry about pulling the cable apart. I have had the cable housing separate from the metal sleeve when I it pulled it out. If you do unbolt the adapter, then cover it with a plastic zip bag.

The H pipe will have to come off and the studs are likely to be very rusty. Soak them with PB Blaster or WD 40 overnight if possible. When you re-assemble the H pipe & exhaust bolts, use lots of antiseize. That way the will be easy to remove next time (yes, there will be a next time!). Use care in disconnecting the O2 sensor wiring that you don't damage the clips that help hold the connector halves together. Be sure to tie wrap (zip tie) the wires out of the way when you re-assemble them.

Identify & mark the neutral safety switch & backup light switch wiring. The connectors are different, but it helps you to get them back on it the right places.

Look at the rubber on the rear trans mount and replace the mount if it is oil soaked or deteriorated. The same goes for the rubber crossmember bushings.

If you have a T5, you may be able to remove the trans & re-install it if you can bench press the 75 lbs that it weighs. If 75 lbs is too heavy, don't hurt yourself, get a trans jack. If your car has a Tremec 3550 or TKO, you will need a helper or trans jack because it weighs 100 + lbs. I built a trans jack from 2x2 angle iron, some swivel casters, 2x4's, 2x6's and a cheap floor jack. PM me if you are interested & I will send you the photos (8 MB) with the write up.

While you are at it, replace the stock cable & quadrant if it is still present. When you buy the cable & quadrant and maybe a firewall adjuster, make sure they are all the same make. That way you have some assurance that they work together. I have a FMS quadrant & cable, & have had no problems with it. The FMS adjustable cable doesn't stretch and operates smoothly. The only thing is that you have to get under the car to make any adjustments. A firewall adjuster would help here to make the fine adjustment.
 
Its actually easy to do, but annoying and painful at the same time. Your really only looking at around 15-20 bolts altogether minus exhaust and they are pretty obvious to see. Its the being on the back under the car with a 75-100 lb tranny that sucks.
REMOVAL:
Disconnect H-pipe
Drain tranny
4 bolts for driveshaft-probably tight
1 nut for clutch cable
1 small bolt for speedo
disconnect electrical plugs
2 tranny mount bolts
2 crossmember bolts
4 tranny bolts
2 starter bolts
6? bellhousing bolts
6? clutch bolts

For install reverse the steps and make sure you use the clutch alignment tool. In some cases the crossmember may not need to be slid back for the TKO but you'll have to see. If it does, that requires a grinder and retacking the welds. The tranny should bolt right up to everything else like the T-5 does. The bitch comes from getting the tranny to slide back in. You have to play with it, jiggle it and so on till it slides in just right. Doing that on your back under the car honestly, is going to suck. But if your persistant and dont get agitated you'll get it done. Figure on a weekend or a very long day if your a first timer, dont have all the tools, and your on your back. The job itself is easy, but not having the right tools and a lift that makes spending $300 worth it. If you have a cherry picker it would actually be easier to yank the whole assembly and change it out of the car. It will take the same amount of time, but its less painful so it may be worth it.
 
All “Fox-Body” Owners that plan to swap a Tremec Style Transmission into their vehicle will have to do the following items:



1.) Different Bellhousing. Tremec made an Aluminum Bellhousing that is a “cheaper” route than a Steel one. However, my personal opinion on Aluminum or Steel is this. Any car making over 450HP to the Wheels needs a Scatter-Shield. I don’t know about you but, I value my Feet!

2.) If you go with a Scatter-Shield you will need to know that the Factory Clutch Fork that is found in the T-5 Bellhousing will not work. Need to buy an extended clutch fork.

3.) Cross-Member will need to have the “Tack-Welds” Grinded off. The “Tack-Welds” are found on each end of the Cross-Member that hold the “Sleeves” in so that they don’t fall out. Once you “Grind” the welds off you will be able to move the Cross-Member either forward or Backward to work with a Number of Different “Manual” Transmissions. In this case you will have to slide the sleeves back so that the Cross-Member comes forward to attatch to a Tremec TKO “Style” Transmission. Remember, the Transmission is “Stronger”, but “Shorter” than the T-5.

4.) You will have to change out the “Slip Yoke” on your Driveshaft to a 31 Spline.

5.) And if you have not already invested into a Adjustable Cable/Quadrant/Firewall Adjuster Kit, now is the time.

Some more info fior you I just copied and pasted.....helped me a little bit.
 
jrichker said:
Labor time: by yourself, first time - 4-6 hours from the time the car gets up on jackstands until the trans sits on the ground & the bellhousing is off. You'll have about the same amount of time to get it reassembled & back in service.

You need both metric & US tools to do the job, the body bolts are metric & the trans mount & engine bolts are US.

The rear driveshaft bolts are 12MM, 12 point and require a first class box end wrench (ring spanner if you are English or Canadian) to remove them. Don't get cheap here or you will regret it. I set the emergency brake and apply a foot to loosen the bolts. Notice the paint marks on the driveshaft & rear end flange: align them the same way they came off. If there aren't any marks, get out your paint spray can & make your own marks.

Be sure to drain the fluid before you remove the trans or you will get to wear it. The best time to do this is before you remove the driveshaft. Have a catch pan in place to get the fluid that comes out of the trans when you pull the driveshaft yoke out. T5's take a good grade of ATF, Tremec 3550 & TKO use 2 3/4 quarts GM Syncromesh at $9+ a quart.

The speedo cable pulls straight out of the adapter, don't pull the clip out of the adapter. It re-installs the same way: push hard on the cable. You can unbolt the speedo cable adapter and pull it out of the trans: this may be the easiest way. Then you don't have to worry about pulling the cable apart. I have had the cable housing separate from the metal sleeve when I it pulled it out. If you do unbolt the adapter, then cover it with a plastic zip bag.

The H pipe will have to come off and the studs are likely to be very rusty. Soak them with PB Blaster or WD 40 overnight if possible. When you re-assemble the H pipe & exhaust bolts, use lots of antiseize. That way the will be easy to remove next time (yes, there will be a next time!). Use care in disconnecting the O2 sensor wiring that you don't damage the clips that help hold the connector halves together. Be sure to tie wrap (zip tie) the wires out of the way when you re-assemble them.

Identify & mark the neutral safety switch & backup light switch wiring. The connectors are different, but it helps you to get them back on it the right places.

Look at the rubber on the rear trans mount and replace the mount if it is oil soaked or deteriorated. The same goes for the rubber crossmember bushings.

If you have a T5, you may be able to remove the trans & re-install it if you can bench press the 75 lbs that it weighs. If 75 lbs is too heavy, don't hurt yourself, get a trans jack. If your car has a Tremec 3550 or TKO, you will need a helper or trans jack because it weighs 100 + lbs. I built a trans jack from 2x2 angle iron, some swivel casters, 2x4's, 2x6's and a cheap floor jack. PM me if you are interested & I will send you the photos (8 MB) with the write up.

While you are at it, replace the stock cable & quadrant if it is still present. When you buy the cable & quadrant and maybe a firewall adjuster, make sure they are all the same make. That way you have some assurance that they work together. I have a FMS quadrant & cable, & have had no problems with it. The FMS adjustable cable doesn't stretch and operates smoothly. The only thing is that you have to get under the car to make any adjustments. A firewall adjuster would help here to make the fine adjustment.

I'm a big guy and can put up 320lbs on the bench. I guess this means I'll be doing it on my back! :D
 
1990LXDropTop said:
I'm a big guy and can put up 320lbs on the bench. I guess this means I'll be doing it on my back! :D

I'm similar to you ... I can rep 315 for about 4-6 depending on the day. When I did my TKO swap I bought a trans jack from harbor freight for ~ $60. I had done my T-5 about 4-5 times before without a jack of any kind; however, once you feel how heavy that TKO is you'll change your mind. Good luck :nice:

Trans Jack:
http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=39178
 
tunedin302 said:
I'm similar to you ... I can rep 315 for about 4-6 depending on the day. When I did my TKO swap I bought a trans jack from harbor freight for ~ $60. I had done my T-5 about 4-5 times before without a jack of any kind; however, once you feel how heavy that TKO is you'll change your mind. Good luck :nice:

Trans Jack:
http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=39178

Yeah but this aint exactly weight lifting :D
 
I dropped my tranny, did the clutch, rear main, pilot bearing, release bearing etc, and put it back up with the help of one friend. This was on jackstands, barely enough room to move around. If it weren't for that damn pilot bearing, it would have been a cake walk. I brought the tranny down, and put it back up with a jack and it worked great.

I am a very novice "mechanic" as well, so you should be fine with the right tools.
 
I was going to do my 5 speed swap myself, but then a friend who has been working on mustangs for years said he would do it for $200. He had the car done in a few hours. I think it was worth it, who knows how long it would have taken me.