The one thing I wanted but couldn’t find when looking for a Cougar last year was a 4spd. They’re certainly out there but much harder to find, so after driving her for a year I’m going to swap out my automatic for a manual.
I’m going with the complete package from Modern Driveline which arrived in 4 big boxes . T5Z and hydraulic clutch. I’m running the stock 351C 2V so no need for a big power setup. Also switching from the stock 2.75 gears to a 3.50 posi.
I’ll be starting the project this weekend and will document with lots of pictures which will be posted here.
I’ve read a couple of good threads here and on the other site which have been very helpful. I thought it would be interesting to document the experience of trying to get a turnkey kit to see how close it comes to having everything work right out of the box.
it’s a very popular topic and one I’m interested in myself. I’ll be happy to see another well documented write up on it, especially as to whether or not the turnkey kit is worth the money as opposed to assembling your own kit.
I’m sure you could do it on your own for less money (I did it for a song on my old GTO back in the day by crawling through many a bone yard) but a) most of those places are long gone and b) ain’t nobody got time for that
The guys at MD have been fantastic to work with as I asked a million questions before ordering.
Some progress: trans is in! Now working inside the car.
Currently being humiliated by the pedal hanger. It’s loose but won’t come out. Seems hung up by the capture bolts just below the front edge of the insturmenr cluster that support the steering column.
New bits going in. Everything went in perfectly once we figured out that it helps to leave the bell housing bolts a bit loose while sliding the T5 in.
Now work moves to the inside. Let me say that anyone that does this (or any work on the pedals) without removing the steering column is crazy or has tiny hands.
Four hours of grinding and painting later the pedals are looking much better.
The Scott Drake roller bearings were not plug-n-play in my pedal hanger but I think that’s mostly due to the hole on one side getting bent somehow. They’re in now but it took some doing.
Good progress today. Clutch master cylinder is in and pedals in place.
This was far and away the scariest part of this project for me since you get only one chance to cut a 1 3/8" hole in your firewall. Overall it came out fine. In retrospect I’d have moved it 1/4" lower and inboard as it slightly interferes with my fuse box on the inside. I’m going to have to reposition the box which isn’t trivial.
Home stretch now as soon as the new brake booster and rebuilt 3rd member arrive all that will remain is fitting a new driveshaft.
This pic doesn’t look much different but represents another 6 hrs labor. Pedals in and adjusted. Clutch bled. New brake booster mounted. Shifter in. Now all that remains is pumpkin and driveshaft plus dash and cleanup.
Looking good. If you ever do this again, use a saws all to trim the peddle and then file or grind the edge smooth It only took me about 10 minutes to do mine.
. T5Z and hydraulic clutch. I’m running the stock 351C 2V so no need for a big power setup. Also switching from the stock 2.75 gears to a 3.50 posi.
