How to Replace a AOD with a Ford T5 Transmision
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
Shifter weather seal
Clutch kit (pressure plate, clutch disc, and throw out bearing)
Clutch cable clip (secures the cable to the bell housing)
Back-up light harness (Ford part# E7ZZ-15525-A)
T5 transmission cross member
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
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
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:firstname.lastname@example.org?subject=AOD_to_T5_swap
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...