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Rebuilding a Mustang BW T5 with different ratios

sim

sim

Mere Drab Mob
Joined
Jun 12, 2010
Location
Port Moody, BC
So, now that I've finally got around to installing my new(er)
engine, my clutch is slipping.

I have a world class T5 from a 1988 Mustang V8. It needs a
refresh. Tag number is 13-52-169

I have a Kaplhenke adapter and bellhousing, and a spare propshaft
front half.

What I really want is the Z-spec gear ratios.

A new T5z is over $1500.

I'm considering ordering this gear set:
http://www.astroperformance.com/product_info.php/products_id/148

And this seal/bearing/syncro kit:
http://www.astroperformance.com/product_info.php/products_id/757

I have never rebuilt a transmission before, but I have a shop
press and patience. It looks like doing it myself will cost half
as much.

Does anyone have any experience with the Astro gear set?

Any tips on rebuilding a T5? Any better ideas?


Thanks!
 
I am in the EXACT same spot. I have a 3.35 gear set in my box, but want to swap all the guts to a T5z set.

Rebuilding a manual isn't bad (you can find the manual online and read through it before attempting to decide if its what you want to tackle).

There are far too many options on that site to know what I want to order/need to order. A coworker has an Astro T5 in his mustang, and has had no problems... I was also looking at G-Force components.

Jordan
 
I have a pdf of the manual open. It looks very doable.

G-force seems to be the other option, they don't seem to list
prices readily. Astro seems fairly reputable just based on
trolling through forum threads on boards for American cars.

I don't need super bullet proof gears, 300hp is really the top
end of what I think I would want in the car. I do want to freshen
everything though. I want it to be like new.

I guess the thing to do would be to email and get gears and
bearings and syncros and seals with the help of a human.
 
On the Mustang forums, the Astro/A5 stuff has a much better reputation than the G-Force stuff does. If you want to have a more detailed conversation with someone that really knows about it...register at www.corral.net and send a PM to Stan at " SPeace-ATL ". He can tell you a lot about the differences between the G-Force and Astro/A5 stuff.
 
Just helped a buddy rebuild a Triumph GT6 4 speed -- easier in some respects (with exploded views from manual and careful labeling of parts according to numbers on the charts); more difficult in some (a lot more clearance measurements to take - and then shims/parts to buy of appropriate dimensions to get clearances where needed).
 
I've has 2 T5's running G-Force internals. One was a drag car, the other set up
For road courses. Both were 2.95 1st, .88 5th, dog rings, straight cut gears.
They worked great, but the straight cut gears were loud.
One car was running 10.00 1/4mi times and street driven. The other was a track day car with about 425whp.
These were durable enough to survive the abuse with no failures and limited repairs.
 
badvlvo said:
I've has 2 T5's running G-Force internals. One was a drag car, the other set up
For road courses. Both were 2.95 1st, .88 5th, dog rings, straight cut gears.
They worked great, but the straight cut gears were loud.
One car was running 10.00 1/4mi times and street driven. The other was a track day car with about 425whp.
These were durable enough to survive the abuse with no failures and limited repairs.
Click to expand...

Thanks for the input.

I lust after dog rings or faceplated gears for some reason.

The reality is, my power goals top out around 300hp, so I don't
really need the strength of a bulletproof gearset. I do want the
closer ratios though.

The 375hp set from Astro, with a master rebuild kit should come
in under a grand when all is said and done. The big power Astro
stuff seems to start at $1500 or so, just for the gearset. Two or
three grand once complete, I'd estimate. G-force seems to be
comparable in price.
 
sim said:
Thanks for the input.

I lust after dog rings or faceplated gears for some reason.

The reality is, my power goals top out around 300hp, so I don't
really need the strength of a bulletproof gearset. I do want the
closer ratios though.

The 375hp set from Astro, with a master rebuild kit should come
in under a grand when all is said and done. The big power Astro
stuff seems to start at $1500 or so, just for the gearset. Two or
three grand once complete, I'd estimate. G-force seems to be
comparable in price.
Click to expand...

Dog rings suck for just about any street driving, particularly when next to a cop at a traffic light with a triple disc clutch and 12lb flywheel. Real hard to drive smooth, harder to drive slow. And straight cut gears are noisy as hell. If it's a dedicated track car or you really don't mind dealing with that hassle on the street (which I tolerated) it can be fun. Earplugs are recommended.


Either way you go you should be getting quality parts. What do you really want out of this car? There's some compromises that can (and should) be made based on the desired usage, and future upgrade potential.
 
badvlvo said:
Dog rings suck for just about any street driving, particularly when next to a cop at a traffic light with a triple disc clutch and 12lb flywheel. Real hard to drive smooth, harder to drive slow. And straight cut gears are noisy as hell. If it's a dedicated track car or you really don't mind dealing with that hassle on the street (which I tolerated) it can be fun. Earplugs are recommended.
Click to expand...

Yeah, I know these things, and can't rationalize the cost in any
case. I just think I would like it. One of the things I do in
traffic is try to shift really smooth. I had a really good time
in a manual Ford diesel truck with a worn out tranny the other
day. When I nailed a shift in that old turd, it felt good.

I think I could tolerate it in my car, but I certainly can't
justify it.

Either way you go you should be getting quality parts. What do you really want out of this car? There's some compromises that can (and should) be made based on the desired usage, and future upgrade potential.
Click to expand...

Well, I really think 300hp is the high end of what I want.

I autocross occasionally, and have been trying to get out on a
proper track, but those opportunities mostly happen when I'm
expected to be at work. I'm not really interested in actually
racing.

I live near the mountians, and many great driving roads. I like
to drive quickly on them, when appropriate. Public roads are best
taken at 8/10ths or less. I have nothing to prove, and am not
interested in destroying the car, or dying.

I like a good road trip. Cross Canada is awesome. A good cruise
fifth gear for trips is a requirement. I don't expect to see a
situation where accelerating in fifth is appropriate, so the
lowest numerical ratio my engine can spin in reasonable terrain
is probably best.

I also want a nice tight transmission with everything working as
new. I would like the car to shift like something that is not
worn out. I take pride in doing my own work -- rebuilding my own
transmission fits with this ethic. I have time/patience to do it
myself.

I opened up the case of the core T5 I have last night. It looks
pretty good inside.
 
I've used Astro and they're great. Had some issues with bearing pre-load and a call and a whack with a hammer fixed the issue. Shifts are slick - more so than any M46. Will be using them again for my 122 trans.
 
For 300 whp that 169 box will be just fine in stock configuration.
Inspect it, and if there are no issues, run it as is.
The 3.35 first isn't anywhere near as low as the stock m46, and is easy to drive from a stop.
.68 OD is better by far than the M46, so you should see an improvement in mileage on the highway.
Just remember that the tall 5th can keep it spooled for long periods, meaning high EGT and dropping mileage numbers.
 
I got a t5z 2.95 gearset from The Gearbox
http://www.thegearbox.org/t5.html

and the Koyo master rebuilt set for World Class.
I had a WC t5 from a 4 cylinder '91 mustang, gearset swap wasn't too bad

I swapped in a different OD gear two years ago from Astro, a Tremec overdrive pair of gears to make it a little shorter than what ended up with the 2.95 input shaft and the original overdrive gears from the 4cyl gearset.

I had the blue cover shop manual for the rebuild, looks like the pdf on g-force is the same
http://www.gforcetransmissions.com/T-5_Service_Manual.pdf
 
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