T5 gearbox conversion

nickm

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 are available in Australia.

Commodore V6 and V8 VN-VS series 1.
Ford inline 6 and V8. EB series2 -???

All these boxes use this bellhousing pattern (ford and holden)
Making them suitable candidates for the conversion/adapter plates available in the US.

The primary difference between the boxes are the input shaft, gear ratios, and tail shaft shifter placement.

Input shaft

Input shafts are swappable between world class boxes depending on the bearing styles..
You must use a shaft of 9-1/4" to suit the Volvo bell housing and adpater plate. This is the common one from a US mustang box.
Pull the old shaft and count the teeth to see which is suitable.

3.33 gear sets.
Ford Mustang Borg Warner T5 Transmission World Class Input Shaft
part number: 1352-085-025
10 Splines, 23 Teeth and the length is 9 1/4"

2.95 gear set
BW # 13-52-085-020
9.25 in length
10 spline 24T
.67 pilot diameter

SKF bearings have a suitable pilot bearing.

Gear Ratios
In general both 6 cylinders got the 3.33 geat set.
It seems the both Ford and Commodore V8s got the 2.95 ratios
there appears to be a 2.95 box from the XR6 T5z too.

Tail Shaft Housing and shifter placement

200 needs 20 1/2" face to shifter. ????
700 needs 24 1/2" face to shifter.
This is a good source for the measurements
http://people.physics.anu.edu.au/~am..._volvo_240.htm

The Commodore T5 Box has a shifter approximatively 23" back
The Ford T5 is 21 1/2" back

These are the dimensions of the US Mustang box

Remember to add the adapter plate thickness when calculating the overall measurement for the shifter position, usually 1/2".

Tail/Drive shafts.
Can be approached in the same way as the US conversions

Clutch plates
Off the shelf plates are available here. They suit the dished flywheel set up.
The Exedy catalogue has a clutch plate that is suitable
http://www.exedy.com.au/clutch-finder
using the new ford input shaft
Size 228mm

Spline OD 27.5
No. of Teeth 10

Gearbox Mounts
will be the same or similar to the US conversions
a 700 Auto cross member seems the easiest way to mount the T5 in a 700

Adapter Plates

There are several available. But The Avalache kit seems the simplest install.
Now called "Dee works" available from
RSI http://yhst-26451710505916.stores.ya.../b2t5trad.html
or Yoshifab
http://yoshifab.com/store/index.php?...&productId=108

You use the standard manual setup from the respective vehicle. Same cluch fork and slave cylinder setup

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This is a great resource about these transmissions. It gives you a chance to see how similar the Australian units are to the US.

http://www.flatheadv8.org/T5Rebuild.pdf

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Ok got some progress on a conversion for a 740.
I have an Australian commodore T5 box here.
Shifter to face 23".
Input shaft 23T - 250mm.

Got some better pricing on making up adapter plates, down to $150 CNC milled from the CAD file in 20mm Aluminium.
70mm is way to pricey
So still leaves the shaft length
The mustang 23t should work will order one. ($110including postage)

All up shifter 30mm to short (not bad? compared to the US) just a little extension.
Tail shaft shorten the AW71 2 peice and add a 1310 yoke.

Question as the release bearing(throwout) is my next part to sort out.

Can any one see a reason not to machine down the T5's bearing retainer so it runs into the Volvo throwout bearing. The Avalanche adapters seem not to have an issue with this thickness?
This rather than machine the bellhousing to accept the T5 shaft and use a T5 release bearing?

nickm

uploaded some photos to my page here.

This is for a 700-900 series needing a 24 1/2" length shifter.

Adapter plate
Got a plate water cut from the CAD file here in 12mm plate. $30 stock and $50 cutting. Fits great. PM me if you want the company that did it.

From a V6 commodore box I used a Mustang input shaft, the one that fits the 3.33 gear set.
Ford Mustang Borg Warner T5 Transmission World Class Input Shaft
part number: 1352-085-025
10 Splines, 23 Teeth and the length is 9-1/4

I used a unmodified M46 Bell housing

The clutch bearing carrier on the bell housing was reamed out about .1mm to fit the input shaft.

From the photos you can see I used a locating ring with the T5s bearing retainer.
This could have been done differently if the guys who did the machining had been a little more careful.

jonbot

i have an E series coon box here

ill try to remember to measure it, i think its pretty similar to the commy box

Vee_Que

Have the bearing cone and adaptor plate drilled and tapped with the bellhousing at the attached now. Next step pilot bearing, mount for crossmember and not much else from the looks of it once I have the tailshaft sent off

Major Ledfoot

Are the dimensions for the 240 the same as for a late-model 140? (i.e. originally designed for the M40 with the extension housing and the short shift lever)

Present plan is to fit L-block B230 sitting upright, with 16v head, +t, into a 1974 142 - and thus a strong 'box with sensible radios is needed.

Also AFAIK Deeworks also sells the kit direct.

deeworks.ca/en/t5.html

nickm

Measure your block face to shifter and compare to a m46. Can't say about the tunnel. Or whether you will need open the hole in the floor a bit.
What I do know is that the mustang T5 with a 19.5" shifter position is not a very common box in Australia.The Australian ford T5 shifter sits about 1 or 1.5" further back. If @jonbot measures it then you will know if any cutting needs to be done.
Seeing the deeworks kit you can use an upright mount for the box.
The commodore box is better suited to the 700-900.

jonbot

E series T5 is 21 1/2 inches

Close enough to suit either, 1/2" shorter than the Commy T5

nickm

thanks... so will a ford t5 shifter pop out the hole in a 200 or do you need to cut metal? for a 700 it's a bit short....ash tray and fuse box.

jonbot

nickm;31594 wrotethanks... so will a ford t5 shifter pop out the hole in a 200 or do you need to cut metal? for a 700 it's a bit short....ash tray and fuse box.

Half an inch shorter than a Commy T5

Though you have conflicting measurements

Its close enough that it should work for a 200

nickm

23" vs 21 1/2 from my photo.

IIRC that was not including the adaptor plate. So about 1 1/2" different.
When looking at the 2 the difference is notability more than 1/2"

jonbot

nickm;31663 wrote23" vs 21 1/2 from my photo.

IIRC that was not including the adaptor plate. So about 1 1/2" different.
When looking at the 2 the difference is notability more than 1/2"

Pic not work on my phone :P

Close enough for me, 940 dosnt have an ashtray or stereo any more anyway

Realistically better suited to a 200 but for $120, I'm not going to complain

nickm

:) the one above with the rule next to it..

even if you install the ford one, it would be easy to swap it to a commodore box

jonbot

once i break the falcon one with a falcon turbo on 16v thing

Ex850R

Get a Holset and give me that XR6 Garrett snail!

jonbot

Hmmmm....

No

:P

volvodriverman

Peaked interest for 240 application as another m46 asssploded 3rd...

jonbot

falcon bawks, mustang input shaft, adapter and clutch from yoshifab

something something tailshaft

(assuming youre into off the shelf parts)

volvodriverman

That the technical version?:-P

jonbot

i am qualified you know

qualified in what, i have no idea

egads (she/her)

"Qualified" he said. See the world he said!