The T5 Transmission Swap Thread

[Whizbang]

The goal of this thread is to provide a complete break down of transplanting a T-5 transmission behind your rotary. Currently i am gathering parts for the swap, should be completed by summer at the latest. Depends on how long the rally project takes. So the first few posts will be reserved but i can be the information dump. I will include the whole install and probably a break down and comparison between the mazda smooth case and the T-5 of course with pictures.


Selecting a T-5

The greatest feature of the T-5 is it's wide use across several manufactures. Borg Warner sold them to everyone from Volvo to Nissan, Ford to GM. There has been such a variety of options produced including two bolt patterns, several tail housings, multiple shifter locations, a dozen gear sets, etc that you can piece together something to fit your needs. Couple that with an extensive aftermarket and you have yourself a very good setup.

World Class (WC) vs. Non World Class (NWC)

You can thank Ford of UK and the Sierra RS Cosworth project for the development of the World Class T-5 during the mid 80s. The T-5 was enhanced to handle the higher power, higher revving turbo engine in the Sierra. The World Class T-5 added taper roller bearings to the counter shaft, needle roller bearings between the first, second, third gear hubs and the main shaft; fiber lined third and fourth gear synchronizer blocking rings; three-piece first and second gear synchronizer assemblies. (From the Workshop Motorsports "How to Rebuild and Modify Manual Transmissions")

The older design of the T-5 was since dubbed the "non world class". Kinda how we now have World War I and World War II. Simply put, there is no reason to choose a NWC model T-5 over a WC model. Also be aware there are items that are not interchangeable between the NWC and WC, these will be addressed in another section.

Which T-5 is right for you?

For starters, you need to know what your goals are. For nearly all builds, the lower gear sets found behind V8 cars are the best factory choice. The Four cylinder gear boxes are found with first gear ratios of 3.76, 3.97, 4.03 and 4.30. These are inherently weaker simply by the nature of the gear ratio itself. Add that with the torque multiplication the gearing provides and you get yourself a weaker transmission. Plus the ratios are terrible anyway with a large drop between first and second. From here you can address which gear ratio you want from the charts below. The 2.95 gear set is rated higher than the 3.35 for earlier cases but later improvements in design also increased the torque ratings.

Starting in 1990, the T-5 saw some improvements in the form of a high nickel steel alloy being used for the second and third driven gears as well as the input shaft. At the same time the ratios for these gears were changed. This resulted in Borg Warner increasing the rating to 300 lb-ft. For use in the 1993 til around 1996 another top end version of the T-5 was produced for the Ford Mustang Cobra. This unit came with a tapered roller bearing between the input shaft and and main shaft and allowed for higher preloads than former designs. Additionally, a steel input bearing retain was used (something found in many of the GM T-5s) in place of the aluminum one. A reverse sychnro was also added in the this model.

At the same time a Ford after market transmission was put out that was modeled after the Cobra transmission just with a better, closer ratio 2.95 gearset and a shorter throw. This was known as the "z" spec transmission and is about as good as it gets without going to something higher end (Richmond gear, TREMEC TKO500/600, G Force, etc)

Additionally, there are many extensions housings and main shafts that can be used to vary your shifter location. Any extension housing can be used with similar length main shafts, but you can not swap main shafts between NWC and WC transmissions.

World Class T-5 Transmission Tag Number Breakdowns

Just because the car came with a T-5 doesn't mean its the one it rolled off the factory with. The T-5 has such great interchangeability, it helps to check the tag information usually located on the extension housing bolts. Below are the tag numbers and information breakdown of many of the WC transmissions you will come across.

Tag #.........Gear Set.......Model Chassis and Year

1352-114.....14................Ford 1985-1986 t-bird/Mustang 2.3L Turbo
1352-115.....01................Ford SVO V8 5.0
1352-116.....07................Ford SVO 2.3L Turbo
1352-126.....03................Ford 1985 Mustang/Capri 5.0
1352-134.....02................Ford Sierra 2.0 L4 Turbo
1352-141.....03................Ford 1986-1987 Mustang/Capri 5.0
1352-154.....15................Ford 1987 Mustang/Capri 2.3 L4
1352-155.....11................Ford 1987 T0Bird /Cougar 2.3 L4 Turbo
1352-159.....08................GM 1986 Camaro / Firebird 5.0
1352-160.....08................GM F Cars 5.0 L69
1352-165.....11................Ford 1986 Mustang 5.0
1352-167.....11................Ford 1986.5 T-Bird/Cougar 2.3 L4 Turbo
1352-168.....08................Ford 1986.5 SVO Mustang 2.3 L4 Turbo
1352-169.....03................Ford 1986.5 Mustang / Capri 5.0
1352-174.....02................Ford 1985 Sierra 2.0 L4 Turbo
1352-175.....01................GM 1988 Camaro / Firebird Racing 5.0
1352-176.....01................GM 1988 Camaro 5.0 TBI
1352-177.....13................GM 1988 Camaro / Firebird 2.8 V6
1352-184.....02................Ford 1988 Sierra 2.0 L4 Turbo
1352-194.....11................Ford 1989 Mustang 2.3 L4
1352-195.....01................GM 1989 Camaro / firebird L89 5.0
1352-196.....08................GM 1989 Camaro / Firebird LO3 5.0 TBI
1352-197.....13................GM 1989 Camaro / Firebird LB8 2.8 V6
1352-198.....??................Isuzu Rodeo
1352-199.....05................Ford 1990 Mustang 5.0
1352-200.....01................Ford 1989 SVO Mustang / Aftermarket
1352-202.....02................Ford SVO / Aftermarket
1352-203.....??................Panther Solo
1352-204.....03................Ford Mustang 5.0
1352-205.....??................Melroe Spray Coupe
1352-207.....11................Ford 1991 Mustang L4 Coupe
1352-208.....05................Ford 1992 Mustang 5.0
1352-209.....11................Ford 1992-1993 Mustang 2.3 L4
1352-210.....13................GM 1993 Camaro / Firebird 3.4 V6
1352-212.....08................GM 1992.5 Camaro / Firebird
1352-213.....08................GM 1992.5 Camaro / Firebird
1352-214.....13................GM 1992.5 Camaro / Firebird 3.4 V6
1352-215.....??................Isuzu 1993 Rodeo 2.0 L4
1352-216.....15................GM 1993 S-Truck 2.2 L4
1352-218.....05................Ford 1993 Mustang GT 5.0
1352-219.....05................Ford 1993.5 Mustang 5.0
1352-220.....04................Ford 1993.5 Mustang 3.8 V6
1352-221.....15................GM 1993 S-Truck
1352-222.....09................GM 1993 S-Truck 2.8 V6
1352-223.....??................BW 4x4
1352-225.....02................Ford Afermarket Mustang V8
1352-226.....15................Ssangyong FJ 4x4
1352-227.....01................Ford SVO No reverse Brake
1352-228.....??................GM 2.8 V6
1352-229.....04................Melroe Sprayer
1352-232.....??................GM 1993 S-Truck 2.8 V6
1352-233.....09................GM 1993 S-Truck 2.5 L4
1352-234.....09................GM 1993 S-Truck 2.5 L4
1352-236.....04................Ford 1994.5 Mustang 3.8 V6
1352-237.....12................Ssangyong
1352-238.....04................Ford Mustang 3.8 V6
1352-239.....05................Ford 1992-1993 Mustang 5.0
1352-240.....02................TVR 1999 Griffith 4.3 V8
1352-242.....05................Ford 1994 Mustang Cobra 5.0
1352-243.....15 ................Ssangyong 4x4
1352-244.....12................Ssangyong 1994 Korenda Diesel
1352-245.....09................GM 1994 Camaro / Firebird V6
1352-246.....05................Ford 1994 Mustang 5.0
1352-247.....09................GM Camaro / Firebird V6
1352-248.....02................TVR
1352-249.....01................Ford Mustang All 5.0
1352-250.....10................Isuzu 1996 Rodeo 2.6 L4
1352-251.....01................Ford Aftermarket pre-1993 Mustang 5.0
1352-252.....10................Isuzu 1995.5
1352-253.....05................Ford Aftermarket 1994-1995 Mustang
1352-254.....06................P/Tech Megastar 4x2 Lotus 2.2 TB
1352-255.....12................Ssangyong
1352-256.....12................Ssangyong
1352-257.....15................Nissan 4x4 w/ 1354 Transfer Case Mount
1352-260.....05................Ford 1999-2001 Mustang Electronic Speed Sensor 3.8 V6


Key.....1st.....2nd.....3rd.....4th.....5th

1.........2.95....1.94....1.34.....1.......0.63
2.........2.95....1.94....1.34.....1.......0.80
3.........3.35....1.93....1.29.....1.......0.68
4.........3.35....1.93....1.29.....1.......0.72
5.........3.35....1.99....1.33.....1.......0.68
6.........3.35....1.99....1.33.....1.......0.83
7.........3.50....2.14....1.39.....1.......0.78
8.........3.50....2.14....1.36.....1.......0.78
9.........3.76....2.18....1.42.....1.......0.72
10........3.76....2.18....1.42.....1.......0.81
11........3.97....2.34....1.46.....1.......0.79
12........3.97....2.34....1.46.....1.......0.85
13........4.03....2.37....1.49.....1.......0.76
14........4.03....2.37....1.49.....1.......0.81
15........4.03....2.37....1.49.....1.......0.86

[Whizbang]

The goal of this thread is to provide a complete break down of transplanting a T-5 transmission behind your rotary. Currently i am gathering parts for the swap, should be completed by summer at the latest. Depends on how long the rally project takes. So the first few posts will be reserved but i can be the information dump. I will include the whole install and probably a break down and comparison between the mazda smooth case and the T-5 of course with pictures.


Selecting a T-5

The greatest feature of the T-5 is it's wide use across several manufactures. Borg Warner sold them to everyone from Volvo to Nissan, Ford to GM. There has been such a variety of options produced including two bolt patterns, several tail housings, multiple shifter locations, a dozen gear sets, etc that you can piece together something to fit your needs. Couple that with an extensive aftermarket and you have yourself a very good setup.

World Class (WC) vs. Non World Class (NWC)

You can thank Ford of UK and the Sierra RS Cosworth project for the development of the World Class T-5 during the mid 80s. The T-5 was enhanced to handle the higher power, higher revving turbo engine in the Sierra. The World Class T-5 added taper roller bearings to the counter shaft, needle roller bearings between the first, second, third gear hubs and the main shaft; fiber lined third and fourth gear synchronizer blocking rings; three-piece first and second gear synchronizer assemblies. (From the Workshop Motorsports "How to Rebuild and Modify Manual Transmissions")

The older design of the T-5 was since dubbed the "non world class". Kinda how we now have World War I and World War II. Simply put, there is no reason to choose a NWC model T-5 over a WC model. Also be aware there are items that are not interchangeable between the NWC and WC, these will be addressed in another section.

Which T-5 is right for you?

For starters, you need to know what your goals are. For nearly all builds, the lower gear sets found behind V8 cars are the best factory choice. The Four cylinder gear boxes are found with first gear ratios of 3.76, 3.97, 4.03 and 4.30. These are inherently weaker simply by the nature of the gear ratio itself. Add that with the torque multiplication the gearing provides and you get yourself a weaker transmission. Plus the ratios are terrible anyway with a large drop between first and second. From here you can address which gear ratio you want from the charts below. The 2.95 gear set is rated higher than the 3.35 for earlier cases but later improvements in design also increased the torque ratings.

Starting in 1990, the T-5 saw some improvements in the form of a high nickel steel alloy being used for the second and third driven gears as well as the input shaft. At the same time the ratios for these gears were changed. This resulted in Borg Warner increasing the rating to 300 lb-ft. For use in the 1993 til around 1996 another top end version of the T-5 was produced for the Ford Mustang Cobra. This unit came with a tapered roller bearing between the input shaft and and main shaft and allowed for higher preloads than former designs. Additionally, a steel input bearing retain was used (something found in many of the GM T-5s) in place of the aluminum one. A reverse sychnro was also added in the this model.

At the same time a Ford after market transmission was put out that was modeled after the Cobra transmission just with a better, closer ratio 2.95 gearset and a shorter throw. This was known as the "z" spec transmission and is about as good as it gets without going to something higher end (Richmond gear, TREMEC TKO500/600, G Force, etc)

Additionally, there are many extensions housings and main shafts that can be used to vary your shifter location. Any extension housing can be used with similar length main shafts, but you can not swap main shafts between NWC and WC transmissions.

World Class T-5 Transmission Tag Number Breakdowns

Just because the car came with a T-5 doesn't mean its the one it rolled off the factory with. The T-5 has such great interchangeability, it helps to check the tag information usually located on the extension housing bolts. Below are the tag numbers and information breakdown of many of the WC transmissions you will come across.

Tag #.........Gear Set.......Model Chassis and Year

1352-114.....14................Ford 1985-1986 t-bird/Mustang 2.3L Turbo
1352-115.....01................Ford SVO V8 5.0
1352-116.....07................Ford SVO 2.3L Turbo
1352-126.....03................Ford 1985 Mustang/Capri 5.0
1352-134.....02................Ford Sierra 2.0 L4 Turbo
1352-141.....03................Ford 1986-1987 Mustang/Capri 5.0
1352-154.....15................Ford 1987 Mustang/Capri 2.3 L4
1352-155.....11................Ford 1987 T0Bird /Cougar 2.3 L4 Turbo
1352-159.....08................GM 1986 Camaro / Firebird 5.0
1352-160.....08................GM F Cars 5.0 L69
1352-165.....11................Ford 1986 Mustang 5.0
1352-167.....11................Ford 1986.5 T-Bird/Cougar 2.3 L4 Turbo
1352-168.....08................Ford 1986.5 SVO Mustang 2.3 L4 Turbo
1352-169.....03................Ford 1986.5 Mustang / Capri 5.0
1352-174.....02................Ford 1985 Sierra 2.0 L4 Turbo
1352-175.....01................GM 1988 Camaro / Firebird Racing 5.0
1352-176.....01................GM 1988 Camaro 5.0 TBI
1352-177.....13................GM 1988 Camaro / Firebird 2.8 V6
1352-184.....02................Ford 1988 Sierra 2.0 L4 Turbo
1352-194.....11................Ford 1989 Mustang 2.3 L4
1352-195.....01................GM 1989 Camaro / firebird L89 5.0
1352-196.....08................GM 1989 Camaro / Firebird LO3 5.0 TBI
1352-197.....13................GM 1989 Camaro / Firebird LB8 2.8 V6
1352-198.....??................Isuzu Rodeo
1352-199.....05................Ford 1990 Mustang 5.0
1352-200.....01................Ford 1989 SVO Mustang / Aftermarket
1352-202.....02................Ford SVO / Aftermarket
1352-203.....??................Panther Solo
1352-204.....03................Ford Mustang 5.0
1352-205.....??................Melroe Spray Coupe
1352-207.....11................Ford 1991 Mustang L4 Coupe
1352-208.....05................Ford 1992 Mustang 5.0
1352-209.....11................Ford 1992-1993 Mustang 2.3 L4
1352-210.....13................GM 1993 Camaro / Firebird 3.4 V6
1352-212.....08................GM 1992.5 Camaro / Firebird
1352-213.....08................GM 1992.5 Camaro / Firebird
1352-214.....13................GM 1992.5 Camaro / Firebird 3.4 V6
1352-215.....??................Isuzu 1993 Rodeo 2.0 L4
1352-216.....15................GM 1993 S-Truck 2.2 L4
1352-218.....05................Ford 1993 Mustang GT 5.0
1352-219.....05................Ford 1993.5 Mustang 5.0
1352-220.....04................Ford 1993.5 Mustang 3.8 V6
1352-221.....15................GM 1993 S-Truck
1352-222.....09................GM 1993 S-Truck 2.8 V6
1352-223.....??................BW 4x4
1352-225.....02................Ford Afermarket Mustang V8
1352-226.....15................Ssangyong FJ 4x4
1352-227.....01................Ford SVO No reverse Brake
1352-228.....??................GM 2.8 V6
1352-229.....04................Melroe Sprayer
1352-232.....??................GM 1993 S-Truck 2.8 V6
1352-233.....09................GM 1993 S-Truck 2.5 L4
1352-234.....09................GM 1993 S-Truck 2.5 L4
1352-236.....04................Ford 1994.5 Mustang 3.8 V6
1352-237.....12................Ssangyong
1352-238.....04................Ford Mustang 3.8 V6
1352-239.....05................Ford 1992-1993 Mustang 5.0
1352-240.....02................TVR 1999 Griffith 4.3 V8
1352-242.....05................Ford 1994 Mustang Cobra 5.0
1352-243.....15 ................Ssangyong 4x4
1352-244.....12................Ssangyong 1994 Korenda Diesel
1352-245.....09................GM 1994 Camaro / Firebird V6
1352-246.....05................Ford 1994 Mustang 5.0
1352-247.....09................GM Camaro / Firebird V6
1352-248.....02................TVR
1352-249.....01................Ford Mustang All 5.0
1352-250.....10................Isuzu 1996 Rodeo 2.6 L4
1352-251.....01................Ford Aftermarket pre-1993 Mustang 5.0
1352-252.....10................Isuzu 1995.5
1352-253.....05................Ford Aftermarket 1994-1995 Mustang
1352-254.....06................P/Tech Megastar 4x2 Lotus 2.2 TB
1352-255.....12................Ssangyong
1352-256.....12................Ssangyong
1352-257.....15................Nissan 4x4 w/ 1354 Transfer Case Mount
1352-260.....05................Ford 1999-2001 Mustang Electronic Speed Sensor 3.8 V6


Key.....1st.....2nd.....3rd.....4th.....5th

1.........2.95....1.94....1.34.....1.......0.63
2.........2.95....1.94....1.34.....1.......0.80
3.........3.35....1.93....1.29.....1.......0.68
4.........3.35....1.93....1.29.....1.......0.72
5.........3.35....1.99....1.33.....1.......0.68
6.........3.35....1.99....1.33.....1.......0.83
7.........3.50....2.14....1.39.....1.......0.78
8.........3.50....2.14....1.36.....1.......0.78
9.........3.76....2.18....1.42.....1.......0.72
10........3.76....2.18....1.42.....1.......0.81
11........3.97....2.34....1.46.....1.......0.79
12........3.97....2.34....1.46.....1.......0.85
13........4.03....2.37....1.49.....1.......0.76
14........4.03....2.37....1.49.....1.......0.81
15........4.03....2.37....1.49.....1.......0.86