T5 gearbox conversion

Barwick10 · 2015-01-12T08:51:19+00:00

Cut from my turbo bricks post forums.turbobricks.com/showthread.php?t=244360&highlight=australian+t5%2A Lets look at what common world class T5 boxes ar...

Major Ledfoot

Tree;65705 wroteBad news. Horrible news. Life threatening news. The 1352-085-050 that I ordered has a different angle to the input shaft on my AU Falcon T5 so it DOESN'T FIT. @bpg, you were right...

Ouch! :( Sorry to hear this mate, I'd hoped what I'd read elsewhere was wrong!

Yet to be confirmed, but It would appear the Ford 6 cylinder boxes with the tapered pocket bearing and 3:25:1 first gear use a unique-to-Australia cluster with a higher helix than US versions. The boxes used in Aussie V8s however appear to use the US-type 1352-077-070 cluster.

Now that it's stopped raining, I've managed to have a more in-depth look at the 0557-006 BA turbo box. Pix shortly.

Rick122S

bgpzfm142;65663 wrote
Wonder how @Rick122S is going with his conversion?

Stalled at the moment, I've only been back at work for a week and have been putting the rear axle back in.
After speaking with Alex, I'll check the angle of the teeth on my input shaft and compare it to the EL and EA boxes.

nickm

Seems a BA box is a problem...
Solve the Commodore shifter issue looks easier...or steal the tail shaft off a BA and ditch the box.

Major Ledfoot

nickm;65710 wroteSeems a BA box is a problem...
Solve the Commodore shifter issue looks easier...or steal the tail shaft off a BA and ditch the box.

AFAIK Tree is using an AU box.

However, the BA Turbo 0557-006 box has a 24 tooth, fine (edit:: 23) spline input shaft and it may well be the same as the AU.

If my BA box and Tree's AU box have the same input shaft, they'll need a 24-tooth replacement - hopefully it's just that the -050 shaft has one tooth too few* for Tree. To recap what's available -

The 1352-085-025 Input is 23 Tooth, 9 1/4" Overall Length, regular WC, 10-spline.
The 1352-085-050 Input is 23 Tooth, 9 1/4" Overall Length, WC Tapered Pocket Bearing, 10-spline.

The 1352-085-020 Input is 24 Tooth, 9 1/4" Overall Length, regular WC, 10-spline.
The 1352-085-060 Input is 24 Tooth, 9 1/4" Overall Length, WC Tapered Pocket Bearing, 10-spline.

If the US 24 tooth and the BTR 24 tooth shafts aren't compatible, there's always the option of changing the extension housings over, as you suggested.

FWIW, this is the input shaft of the BA Turbo box. This is a number stamped on it. Heaven knows what it is or meant to be. Note the fine splines.

(EDIT: Well, looks like these are the numbers! 0557-085081, found on a Gumtree ad)

Here's the tag.

As can be seen from this pic of the transmission face side of the bellhousing, Ford / BTR didn't use a separate bearing retainer for this box; they made it part of the bellhousing. So here you can see the oil seal and the bits you'd usually find in the bearing retainer.

If you're using this box, you'll need one of these. The one on the right (with all the scoring) is the aluminum tube version; the steel version (the one you want) is on the left.

It's a BTR-made bellhousing - note the '0557' part number.

Looking inside this box, there are a lot of metal 'floaties' in it. What certainly hasn't helped the box is the fact that someone has put regular gear oil in it instead of the recommended lube... which has likely put it well beyond the before-mentioned '69' and into the region of '4K...

Ah, well, I bought it knowing it was going to need a rebuild or was only good for parts.

Vee_Que

nickm;65710 wroteSeems a BA box is a problem...
Solve the Commodore shifter issue looks easier...or steal the tail shaft off a BA and ditch the box.

Au box tail section with vs box, however, they aren't as strong. Maybe an el box can do the job. We will see.

Major Ledfoot

Vee_Que;65733 wrote Au box tail section with vs box, however, they aren't as strong. Maybe an el box can do the job. We will see.

How many teeth were on the input shaft which came out of Tree's box - 23 or 24?

Vee_Que

I counted twice. Im sure they are both 23.... Argh. But i had been up since 4am.

nickm

Grab a white board marker and mark the teeth as you count. My mistake about the au-ba thing. My understanding is the ratios on the commodore box dictate the torque limit.
There is a bilet plate for the layshaft that is supposed to increase the strength.
If these boxes are world class you may be able to swap the internals so the input shaft matches the layshaft.

PaddlerEd

Rick, where are you in WA? I might have a mate coming over to the Northern NSW Tablelands from Kununurra with a ute so may be able to lob some back load in if you needs moving... Bruce couriers at their best (Lach doesn't know this yet...)

Vee_Que

Yeah, they are around. As are complete gearsets...

Elliot

Well I had gathered some parts for my conversion (Using DeeWorks adaptor plate)
Have AU falcon series 1 gearbox

Now unsure what to do re input shaft, as it appears that any mustang input shaft isn't compatible?

From what I understand my input shaft is 167 vs 182 on the mustang which is required for the kit to work :(

Vee_Que

It looks like there is a way, will keep people updated!

Major Ledfoot

Elliot;66044 wroteWell I had gathered some parts for my conversion (Using DeeWorks adaptor plate)
Have AU falcon series 1 gearbox

I've ordered a couple of adaptor plates from @Vee_Que and I also have a DeeWorks kit on order.

If the tag number on your gearbox is not WR2A-7003-AA / 557-001 - could you please post the numbers on the tag?

Also, what are is the casting number of the gearbox extension housing? (Should be a nine-digit number starting with '0552' or '0557' and below the shifter on the left-hand (port) side of the gearbox). <p>

Now unsure what to do re input shaft, as it appears that any mustang input shaft isn't compatible?

From what I understand my input shaft is 167 vs 182 on the mustang which is required for the kit to work :(

For the second part of your question: yes. The DeeWorks kit presumes you're using an input shaft of 9.25 inches total length, which gives a shaft length of 7.18 inches (182 mm) from transmission face to tip.

For the first part - well, it's by no means certain that no so-called Mustang shaft will fit. There appears to be two considerations before ordering an input shaft for an Aussie T5 of the required length -

1. How many teeth are on the input shaft being replaced (23 or 24 teeth); AND

2. If the input shaft bearing is of the regular type or is the tapered pocket bearing type.

The big question right now is if some Aussie 6-cylinder Ford T5s have a unique helix angle on their input shaft and cluster gears. If they don't, then it's just a matter of swapping the input shaft and preloading the replacement correctly. A previous successful conversion on @blondejay's car was done with a V6 Commodore T5 box, and only required an input shaft change with a regular (i.e. non-pocket bearing) unit.

Tremec offers both 23-tooth and 24-tooth input shafts of 9.25 inches total length, which is what we need for these kits and plates to work , and each are available in either the tapered pocket bearing type or the regular type. See my previous post (just updated) with the BA turbo box pictures for the part numbers for each.

If the input shaft is 22-tooth, that gearbox will be using the weak 35T-31T-23T-15T-15T cluster (1352-077-050), a weak 33-tooth 1st gear (1352-080-032); the weak version of the 31-tooth 2nd gear (1352-080-037), and the barely adequate 27-tooth 3rd gear (1352-083-002)... and I cannot find a 22-tooth version of a of 9.25 inch total length input shaft. Which is perhaps a blessing.

Elliot

Thanks for the info!

The tag info on my box:

WR2A-7003-AA
0557-001
0557-866906 A

Elliot

Also what is everyone using clutch wise?
I'm guessing the cheapest option is just to replace the friction disc with a ford one? part numbers anyone?
Also who's done a flat flywheel conversion, what are the options there?

Vee_Que

I'm doing the flat flywheel conversions to a falcon pp and clutch. Pm me for more info.

deleted_user_160

And I'm currently running the exedy ford clutch kit. Spent ages working out all the correct sizes and appropriate parts to make it work.

And it's going well. With the new clutch in comparison to the ford disc in the Volvo stepped fly combination, no more slipping as I come into power.

Tree

Almost there!
Plenty pictures have been taken, will do a full write up when I have time + parts list
<img src="https://ozvolvo.org/uploads/FileUpload/98/5edbe417ff4fd9124ca702c5688b17.jpg" />
<img src="https://ozvolvo.org/uploads/FileUpload/b0/3797b31fdfe1d29138bde18292e351.jpg" />
Lengthened falcon input shaft by 17mm

timbo

nickm

What did you do to the shaft? How was it done?

« Previous Page Next Page »