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  AOD to T5 Conversion Help!! (Long)

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Author Topic:   AOD to T5 Conversion Help!! (Long)
GTRocks
Gearhead

Posts: 3631
From: Lusby, MD
Registered: Jun 99

posted 09-28-2002 11:51 PM     Click Here to See the Profile for GTRocks   Click Here to Email GTRocks     Edit/Delete Message   Reply w/Quote
Well I finally started the swap. The pedal assembly that I put in came out of an '89 I think. It was a 4-speed assembly, but I put the 5.0 clutch pedal on it (long story). Anyway, after much labor, the pedals are in. However, when I went to hook everything up, there are some strange problems. The pedal assembly that I put in seems to have two electrical connectors for the clutch rod. One on the clutch pedal side seems to sense when the clutch is engaged (assuming this is the neutral safety switch that doesn't allow engine start unless the clutch is engaged). The electrical connector for this sensor was filled with spare connectors found on the sidewall as expected. The weird part is that the pedal assembly also has some sort of electrical gizmo attached to the opposite side of the assembly. It seems to be activated by the clutch being in the non-engaged state. I don't have a clue what to attach to these two connectors (one sensor, two small connectors). Anyone help here?

2. There is a wire that comes off the steering column that routes under the console that connected to the AOD shifter lockout. I'm assuming this is the connector that doesn't allow shifting out of park unless the key is engaged. What should I do with this wire?

3. There is another 5-wire connector (white plug) that I don't have a clue where to connect. I don't remember seeing it when I unhooked everything, and I'm not sure what to do with it either. The shop manual is useless on calling out connectors or wire colors. I could name the colors if someone has documentation as to what I should do with it?

4. We pulled the clutch cable through the firewall, but aren't sure how it should be routed to the fork. Currently we have it going through the "U" of the motor mount so that it is away from the header. This puts the "U-turn" in the cable centered right next to the oil filter. That would seem to not be right for annoyance reasons. Can someone verify the proper routing of this cable?

5. There seem to be two different connection points on the quadrant side of the pedal assembly. One will obviously house the quadrant. The other has a triangle shaped plastic wedge that is spring loaded. Is this supposed to do something? I don't see its purpose other than maybe keeping the clutch cable from scraping the pedal assembly. Also the quadrant also seems to have a spring with it, but I cant see what to attach the straight leg of the spring to. Anyone help there?

These manuals are way vague.

We got the AOD out, but decided to hold off on the T-5 install part. The clutch I had that I was going to put in we decided didn't have much mileage left on it. Hello Summit? Cha-ching....King Cobra on the way.

All in all it was a good day, but I had hoped to be shifting to work on Monday. They told me that was a pipe-dream though.

I have a dream......

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Stewart
Gearhead

Posts: 9743
From: Monterey, CA Mustangsandmore Member #437
Registered: Apr 2000

posted 09-30-2002 04:36 PM     Click Here to See the Profile for Stewart   Click Here to Email Stewart     Edit/Delete Message   Reply w/Quote
1. Not a clue. I'll try to get under my dash tonight and see if I can figure out what you're talking about.

2. I would think taping it off would suffice. I'm not sure, but I would think you wouldn't need to do anything with it.

3. Is this 5-wire connector under the dash also? Where exactly does it come out?

4. Mine comes through the firewall and drops down and attaches to a bracket attached to the fenderwell. The bracket is level with the header pipes, and almost as far forward as the coil. From there, it routes down between the oil filter and the motor mount bracket, then curves back to the tranny.

5. Not sure I understand this one completely. Lemme ask you this, what type of aftermarket quadrant are you using?

Stewart

[This message has been edited by Stewart (edited 09-30-2002).]

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GTRocks
Gearhead

Posts: 3631
From: Lusby, MD
Registered: Jun 99

posted 09-30-2002 07:09 PM     Click Here to See the Profile for GTRocks   Click Here to Email GTRocks     Edit/Delete Message   Reply w/Quote
1. I'm thinking that I'll just leave these alone (open) until I have everything else in place, and see if she runs ok. Nobody seems to have ever seen these before. There's even a number on the side of the connector box (would that help anyone to get it deciphered?). I've had a few people tell me that I'm worrying too much and that there will be left over connectors....maybe they're right, just makes the electrical engineer in me nervous!

2. I'm thinking the same, but its a pretty long cable that I'd like to get out of the way, but it doesn't seem to disconnect easily.

3. The 5-wire connector comes off of the main bundle, is about 6-8" long, wrapped in black tape and ends with a white female connector. I seems long enough to connect to the neutral safety switch, but they are both female, so that's not it. Plus I have the neutral safety switch populated with what I believe to be the correct connections anyway.

4. That sounds like what I did. I'm pretty sure we have it mounted on the fenderwall correctly since the hole was already there. Perhaps it will shorten up a bit when we put the fork in and get it attached. It just seems that the cable goes too far towards the front of the car and essentially does its U-turn right in front of the oil filter. Perhaps we aren't doing a good job of estimating where the fork will be. After that does it go sort of under the motor mount at the base of the steering shaft? There is sort of a tunnel under the motor mount. Currently, I have it running through the tunnel, but maybe it should go on the motor side of the tunnel rather than through? The fender side would seem to put it too near the steering shaft.

5. I got the quadrant as a package deal with the tranny. Not positive as to the brand, but I think it's a BBK. It is aluminum, that much I'm sure of. The two arms on the accelerator side of the pedal assembly house this gray plastic triangle gizmo (held onto the pedal assembly by a cotter pin), and the quadrant. The quadrant fits in front (steering wheel side) of the gray plastic gizmo. I am thinking that the load spring on the quadrant should have its straight arm hook to the plastic gizmo somehow. Maybe?

I'm searching for a 5.0 stick to put my head under!

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GTRocks
Gearhead

Posts: 3631
From: Lusby, MD
Registered: Jun 99

posted 10-01-2002 02:37 PM     Click Here to See the Profile for GTRocks   Click Here to Email GTRocks     Edit/Delete Message   Reply w/Quote
Well, I found an '86 to put my head under. I did route the clutch cable wrong. It goes on the motor side of the motor mount, whereas I had it going through the mount.

He also had the additional electrical connection on the right side of the clutch pedal (it's actually over next to the quadrant). His was hooked up to something under the console. The connection was mounted on the inner side of the console support. I'll have to look in that area to see if there's something that I can connect it to.

His gray plastic wedge that I was worried about was actually meshed into the clutch quadrant. They both have serated edges that meshed. However the aftermarket quadrants don't have the serated edge, so I'm not sure how that's going to work out.

I have some more exploring to do.....

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GTRocks
Gearhead

Posts: 3631
From: Lusby, MD
Registered: Jun 99

posted 10-01-2002 03:48 PM     Click Here to See the Profile for GTRocks   Click Here to Email GTRocks     Edit/Delete Message   Reply w/Quote
Any chance that this "extra" connector on the clutch pedal is for the shift light that the '80s Mustangs had?

Just a thought.....

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Stewart
Gearhead

Posts: 9743
From: Monterey, CA Mustangsandmore Member #437
Registered: Apr 2000

posted 10-03-2002 03:34 PM     Click Here to See the Profile for Stewart   Click Here to Email Stewart     Edit/Delete Message   Reply w/Quote
Dave, I haven't had time to check for you yet, but I'm hoping to work on the 5.0 tonight or tomorrow. I'll see if I can find what you're talking about.

Send me an email. Maybe we can hook up on the phone and look under our dash's at the same time to figure out what's what.

Stewart

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GTRocks
Gearhead

Posts: 3631
From: Lusby, MD
Registered: Jun 99

posted 10-03-2002 07:19 PM     Click Here to See the Profile for GTRocks   Click Here to Email GTRocks     Edit/Delete Message   Reply w/Quote
You have mail!!

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GypsyR
Journeyman

Posts: 53
From: SC
Registered: May 2002

posted 10-13-2002 12:41 AM     Click Here to See the Profile for GypsyR   Click Here to Email GypsyR     Edit/Delete Message   Reply w/Quote
Can't help on too much. I went from 5 speed (and a 2.3) to an AOD. The other switch on the clutch pedal should be the cruise shutoff. As in if you have cruise control on and suddenly step on the clutch, the cruise shuts off. There should a vacuum style switch that does the same thing on the brake pedal. Obviously if you don't have cruise, you don't need either one.
5 pin connector? Might it be the round one that goes to the tranny for the neutral safety and backup light switches? Don't think it's the same type plug on a T5.

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