Few years ago i had the opportunity to drive and later own black&flames's 89 manual box.I still can remember the thrill of driving that car and how excited i was to drop the clutch for the first time.
Years has passed and i finaly got back that little thrill that i missed so much by doing the swap to my daily driver 04crown vic.
It sure bring it's part of challenge but it really worth each and every hour and money put in that project.
Finaly i would like to thank Jeremy (black&flames) for giving me such oportunities and all of you who have done this swap and have been very generous with your info and time quickcrownvic-quickvic30-Funkrider-Metroplex-drock96marquis
Thank you The bold font applies to my 1993 Crown Victoria LX
This write-up is not an exact procedure on how to do it but should be used as a guide.I do not want to be held responsiblefor any missunderstood or mistake during the swap.
This swap should be done by an experienced mechanic with an appropriate facility.
I have used a tremec tr-3650 transmission found in any 01/04 mustang.This transmission will handle better the hp/tq than the t-5 or t-45 found in older model but has it's own problem too.
The second gear syncro is prone to be diffucult to engage when the temperature is cold outside.Ford has made an updated part to resolve that problem and most 04 tremec should not have that problem.That transmission is rated at 360lb/tq and should be fine in most application but if you need something above that i would recomended an up-dated version who can support up to 495lb/tq (see my links at the end) I used a T45 from a 1996 Mustang.Borg Warner T-45 – 5 speed manual transmission has an aluminum alloy gear case, tail housing and bell housing.
The T45 is used only behind the 4.6L Mustangs from 1996 to 1999. Tremec replaced the T-45 with the Tremec 3650 in 2000. It has single rail gear selector and carbon lined steel synchronizer rings.
The T-45 installed in the 1996-1998 GT Mustangs is different than the Cobra Mustangs. The transmission mount position and speedo gear are the main differences.
The Mustang Cobra T-45 has a 7 tooth speedo gear.
The Mustang GT T45 has an 8 tooth speedo gear
In 1999 all T-45's were changed to the Cobra specs.
The T45 case casting number is “1381”
Standard gear ratios on the Borg Warner T45 and Tremec T45:
1st Gear: 3.37
2nd Gear: 1.99
3rd Gear: 1.33
4th Gear: 1.00
5th Gear: 0.67
Rev Gear: 3.22
The Mustang T45 has an input torque rating of 325 ft-lb
For the clutch/pressure plate i went with centerforce.It is a 10 spline unit who was made for the mustang cobra.It require a bit more effort to depress the clutch but it really hold the power.
The unit is quite pricey but you cant really so shop wisely.
The flywhell is a 6 holes billet stell 1:1 ASI approved.
I have been recomemded to NOT use a billet aluminum for this application. I started to go witha King Cobra clutch but found a sweet deal on a new take-out. The flywheel was nodular iron witha stock factory clutch.
Clutch pedal assembly.
I went with the 01/04 mustang brake clutch pedal assembly as a starting point.The mustang cable clutch assembly cannot be used on the crown vic as is so it had to be modified to fit my existing brake pedal. I tried using the Mustang pedal assembly with the backplate from the Crown Vic welded onto it. Too much time and energy wasted try to get everthing to line up.
You will need to grind off the clutch pedal shaft off the mustang assembly to later weld it to the crown vic assembly.
Pay attention to the cleareance with the pcm when you will weld the shaft. Mine has abouth 1/4 inche in betewen. This is the same thing I did.
The clutch pedal itself has to be modified.
You have to drill a hole approximatly one inch lower that the original position and make it square with a file.
Do not mess up with that step as is the square hole is too large the pedal will spin on the shaft. I did NOT do this.
This will make the pedal still sit lower that the two other pedal but since the fuse box is right up there you dont really have the choice. It may look weird but the feeling when you press the clutch isn't.
Since i welded the clutch shaft there is no more space for the brake light switch who was originaly mounted below the abs switch so you will have to mount your own on/off switch ditectly below the shaft or at any other convinient place. I cut and welded the brake and clutch pedal to sit where I wanted it. Some people will not cut these and no shop will do it either because of liability issuses.
The electric harness for the automatic is obviously no longer needed. The only wire who should remain from this harness are the one for the oxygene and vss sensors.You wil have to run 2 extra wire for the reverse light.
A pcm reprogramation (aka a tune)is mandatory for this swap.
I highly recomemded lonnie at blue oval chip. he is specialized in umique swap. (see links at the end) I have the OBD1 system and did NOT need a reprogramming.
The crossmember on any 03+ model has to be modified in order to clear the taill of the transmission.The top has to be cut as well as the front of it.
Even the lip at the bottom end of the transmission needs to be remoove
This step is quite time consuming since you will have to make sure there is absolutly no contact in betewen the two parts.
A gap of 1/4 betewen the crossmember and transmission is required since everything will move during driving condition. I did not have to do any of this.
You need to change the 36 spline yoke for a 28 sline yoke.
A 5/8 lenght drive shaft spacer must be used since the new transmision is shorter than the 4r70w/4r75w.
Most aftermarket compagnies makes them for the mustang but be aware that they used smaller pinion flange so it will not fit the crown vic's one.
It's either you get one custom made at the local machine shop or you swap the pinion flange and joint for the mustang one. If you have an LX model you will not need the spacer.
A rectangle of 3 by 5 inches has to be cut approximatly 3 inches from the abs module for the shifter location.
You will also have to trim a bit of the reinforcement underneath the tunel at the bottom of the rectangle to again clear the transmission.
I have used a hurst short throw shifter.The base is for obviously the tremec but the shifter itself is for the older style of mustang (the fox years).
It is close from the dash but there is plenty of space for your hand. I used a stock shifter for a short period but found a Hurst stick that I liked. I swapped stick and now have more room.
Tremec tr-3650 01/04 mustang
center force clutch/pressure plate
Flywheel 6 bolts
Flywheel bolts F6ZZ6379AA
clutch lever XR3Z7515AA
clutch cable XR3Z7535CA
Clutch bearing F7ZZ7548AA
pilot bearing F6ZZ7600A
Dust shield F6ZZ7513AA
Yoke 28 spline E9TZ4841A
I will up-date this write with your comments and help in order to make it as complete as possible.
If you need more info or have any question i will be glad to answer them all.
you can pm me or write me at [email protected]
Good luck with this swap. All the guys mentioned were my inspiration to get this done and I have had more fun, positive comments and questions than you can imagine.
heres some video of the final results enjoy http://www.youtube.com/watch?v=2PgNDNamCMYhttp://www.youtube.com/watch?v=GXUqY8iAzhshttp://www.youtube.com/watch?v=9MKg-jcTZS4