T5 rebuild, DIY or leave it to the pros?

WhiteFizzo · Sep 26, 2006

I have finally decided to ditch the AOD and do the transmission swap. It won't happen till early next year, but I want to go ahead and get all the parts together. I am trying to keep the costs down for the conversion (aren't we all), so I am thinking about finding a previously loved T5 and getting a rebuild kit. Is it a straightforward process to rebuild the T5, or should I let someone who has done it before take care of it for me? Also, what year range pedal assembly will fit into my 93 LX? 84-95 seems to ring a bell, but I need to know for sure.

Sicarius428 · Sep 26, 2006

Rebuilding is pretty strait forward. I highly recommend the video that will walk you through it. Also recommend replacing the aluminium throw out bearing retainer with the steel one. Also check if the bearings you got in the kit... when you get it. A file should just glide off of them and not bite. I purchased my kit from hanlon motorsports and the roller bearings that go inbetween the input and output shaft were soft. Needless to say my T5 was/is toast. I tested my stock bearings and they were much harder than the new replacements. Anyways also check your shift forks and look for any cracks. The video will also tell you want to look for.
Kevin

WhiteFizzo · Sep 27, 2006

Thanks for the info. Who makes this video and where can I get it? Also, are there any hard to find parts that I should go ahead and start looking for? I am planning on a March/April timeframe for the swap, but anything that I can put in the garage to get in my wifes way is well worth it. I have to put up with dust ruffles and window treatments, so it is only fair that she has to look at car parts stacked in the garage right beside the dryer.

tmoss · Sep 27, 2006

Bob Hanlon (Bangin Bob) made the video - it is very good. You'll need a rebuild kit (~$160), hydraulic press, bearing pullers and may have to replace a gear or two (don't cheap out on that) after inspecting them.

jrichker · Sep 27, 2006

See http://www.ttcautomotive.com/English/onlineorder/product.asp to download a FREE service manual for T5 or Tremec 3550/TKO
You will need the Adobe Acrobat viewer which is also a free download – http://www.adobe.com/products/acrobat/readstep2.html

See http://www.hanlonmotorsports.com/ or http://www.ddperformance.com for parts

A T5 rebuild kit with syncros, bearings and other small parts costs about $160. It does not include any gears or shafts.

http://www.hanlonmotorsports.com/ also has a video on how to rebuild your T5 or Tremec. It costs about $20, and is worth every penny of it.

I did a Tremec 3550 rebuild, and it wasn't that difficult. The video was an immense help, and I would recommend viewing it. At $20, it will give you an opportunity to look and decide for yourself if you think that it is something you want to try to do.

Sicarius428 · Sep 27, 2006

Hanlon has all the parts you need. I purchased a second gear and a 1st-2nd slider gear which were 40 bucks each. The shift fork was about 40 bucks if I remember correctly and the steel throwout bearing retainer can be found there. Ford wanted to sell the gears for 80 bucks a pop so I didn't bother asking after than. Their customer service is good. I may have just gotten a bad batch of bearings... at least what I am hoping.
Kevin

wazazzle · Sep 27, 2006

if you're set on rebuilding yourself.. get the vid and t5 manual. the vid is a great help... but better make sure you have all the tools. i was going to rebuild mine, but only thing i didnt' have was a shop press so i just grabbed a decent one from the pullpart for $65.

71swing · Sep 28, 2006

I purchased the video from Hanlon motorsports a while back. If I still have it (I would have to look for it)But you could have it for free.

After all I'm not using it anymore.

90 · Sep 28, 2006

you can get a 94 peice set for a T-5 at www.summitracing.com for $240 im not sure how many peices are in his for 160, but if your gonna do it your self you might want to spend the x-tra money for the better of the 2 kits.. if its the same amount of peices for 160 then thats a better buy..

vikingpower · Sep 28, 2006

Can a gear puller be substituted for the hydraulic press, or is it something the Napa guys can take care of? I've had various Napa machine shops do stuff in the past.

tmoss · Sep 28, 2006

gear puller will not cut it...........

bullitstang1313 · Sep 28, 2006

Shop press is definately needed. Gear pullers cannot reach far enough to get the gears off of the mainshaft. If you trust that NAPA could remove and install several things for you then you could go that way. You might ask how much it will cost first.

WhiteFizzo · Sep 28, 2006

I am going to get a copy of the video from Hanlon, that way I will know better if it is something that I can do or if I should try to find a rebuilt T5. 71swing, I appreciate the offer. If you can find the video, pm me and we can work something out. Otherwise, I am going to call Hanlon sometime next week and order a copy.

Also, pedal assembly, which years?

Sicarius428 · Sep 28, 2006

Definately invest in a press. I got one from harbor freight for about 100 bucks and you can press out the gears with the gear puller clamp. Machineshop costs could come close to the cost of a press so it's always nice to have another tool around the shop. Especially if you have to do Ujoints or something.
Kevin

tmoss · Sep 28, 2006

Harbor Freight 12 ton press is about $115 on most sales. Got a flyer for a 20 ton the other day for $160.

vikingpower · Sep 28, 2006

The press will have to wait until I have a real garage instead of a gravel parking lot next to my apartment... -sigh-

millhouse · Sep 28, 2006

Or you could do what I did...stop by d&d performance on your way home and have them press it off for free!

Yeah yeah...I got lucky. Once I have the room though I'll be picking up a Harbor Freight El-Cheapo press.

v8only · Sep 28, 2006

the press takes up almost no room at all.

I've been able to gently slide all the gears off the mainshaft with two screwdrivers or a prybar, and haven't needed the press "yet" although I wouldn't attempt this without one.

I just converted my hanlon video to dvd, made life much easier, no more rewind button.

71swing · Sep 29, 2006

Well let see here.

Bald beaver VOL. 2
Eye Contact
Hardballing
My girlfriend best friend

Nope no Hanlon instruction video.

Sorry WhiteFizzo, I looked everywhere for it. Must have got thrown away when I moved last year.

But it looks like I kept the most important ones.

WhiteFizzo · Sep 29, 2006

Thanks for looking.
That is an impressive collection you have there. The question is do you hide them or just leave them lying around.

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