T-5 Rebuild

95/GT/5.0 · 12-17-2002, 11:52 PM

I have had a problem with my T-5 transmission for a few weeks now.The problem:shifting from first to second gear causing a grinding sound and will not go into second gear unless you pause for a second or two then shift into second and still makes a clanck when it goes into second gear.This is the only problem with the trans.All other gears work fine.The transmo has 135K miles on it and was ready for an overhaul anyway.So I purchased a Borg-Warner World Class T-5 master rebuild kit, complete with synchronizers.I removed the trans and installed the rebuild kit.Oh shure sounds easy enough.12 hours later I was finished the rebuild.Everything went back together the way it came out.Also took the opportunity to replace the clutch kit and upgrade the clutch cable.I have rebuilt Borg-Warner Super T-10's (4 speeds) for my Z28 and had no problems with any of them.This T-5 though,is a whole new ball game.Top loaded shifter for one thing. ANY WAY MY PROBLEM AFTER THE REBUILD IS:THE TRANSMISSION STILL HAS THE SAME PROBLEM I DESCRIBED ABOVE WITH SECOND GEAR, ALLTHOUGH NOT AS BAD.Anyone out there with some T-5 rebuild experience that could tell me what I might have missed,and what to look for when i open it back up.Any help would be appreciated.Thanks 1995 5.0 GT owner.

302 LX Eric · 12-18-2002, 08:57 AM

You may want to give D&D Performance or Hanlon Motorsports a call. Both are good people with tons of experience with T5's...

Links:

www.ddperformance.com
www.hanlonmotorsports.com

Hope this points you in the right direction.

E

Conman · 12-18-2002, 10:51 PM

did you properly shim the input bearing?
how did the shift fork look? how about the inside of the 1-2 slider?

95/GT/5.0 · 12-20-2002, 03:42 AM

Hey 302 LX Eric,Thanks for the help.That hanlonmotorsports.com site was a great help.They have told me what to look for and have the parts I may need.That dnd site is cool too.I've had my eye on one of their rebuilt T-5's $849.00 for some time now but If all goes well I wont need it. I'm gonna take the damn thing out again next weekend at my brothers shop.It's not so bad when ya have air tools and a rack.It's just that damn top load shifter.Is there a trick to putting the cover with the forks lined up just right so the shifter works.It took me longer to get that right ,than it took to rebuild it.Maybe I'll ask the guy at hanlonmotorsports.Anyway I'll let ya know how it turns out.Thanks again. 1995/GT/5.0

95/GT/5.0 · 12-20-2002, 03:58 AM

Conman, I did shim the front bearing,there was no visible sign of wear on any of the parts.Forks looked good,notch on shift levers looked good too.No metal in the case either.It was pretty clean for 135K miles.I'm gonna tear it down again after Christmas.*Is there a trick to putting that top cover with the forks back on .That thing drove me crazy.I actualy got it right by accident after 100 tries.Last trans I rebuilt was a Borg-Warner super T-10 4speed and it had an external shifter.That cover just slaps back on.This top loader must be alien technology.Thanks for the help and if ya know anything about that cover re-installation please post again...1995/GT/5.0

Conman · 12-20-2002, 12:22 PM

I don't really remember any tricks because I just threw it on there first try. Maybe I got lucky, I don't know.
make sure the sliders are in the neutral position and the forks are in the neutral position. You kinda have to lower it down and slide it at the same time. Be careful not to wreck your silicon bead though.

88workcar · 12-22-2002, 10:14 PM

You need a 2nd gear and a 1-2 slider. The cover, if you have the tail facing you the cover must be lowered while being over to the right side about an inch an a half, once it is down, slide it to the left, right into place. Very easy.

95/GT/5.0 · 12-24-2002, 01:17 PM

Hey 88workcar.Your the man.You was right about the slider,although the slider wasn't actually bad.It was the syncro keys (winged type) and the syncro spring that keeps the keys in place on the 1st,2nd & ,rev. slider (blocker) that are bad. I also found the blocker slightly off position on the shaft.Being that it is pressed on , it took a few wacks with a rubber malet to get it in the correct position.This couldn't have been helping the situation any.I'm waiting on the parts I ordered from hanlon motorsports.Very inexpensive parts, the keys and a spring..I have a better understanding of how this T-5 works now that I've had to pull it out again, and rip it apart,again!Knowing the sequence of operation helps too.This time I can run it thru the gears before I put the Top shift fork cover on.Thus making shure it goes into 2nd gear good this time. Shoulda done my homework the first time but ,I'll know better next time. I'll let ya know how it went in a week are so.Thanks 95/GT/5.0........................

95/GT/5.0 · 12-26-2002, 05:02 PM

Update.Upon closer inspection I found the 1st,2nd gear slider bad too(a bit worn down).Got one ordered today $85.00 plus S&H $$$ spent on parts to date. World class master rebuild kit w/synchros$165.00,misc.small parts not included in kit $35.00,1st,2nd,gear slider $85.00 better than $1200.00 for a new one. 95/GT/5.0

Conman · 12-26-2002, 10:23 PM

glad you got it figured out and are fixing it

I think being able to do the work yourself helps out huge on the pocket book. The only time my car has been in the shop is when I got new tires and free installation was included. Also I don't have a wheel balancer. Other than that everything gets done by me.

12-17-2002, 11:52 PM	#1
95/GT/5.0 Registered Member Join Date: Dec 2002 Location: Biloxi.Mississippi Posts: 49	T-5 Rebuild I have had a problem with my T-5 transmission for a few weeks now.The problem:shifting from first to second gear causing a grinding sound and will not go into second gear unless you pause for a second or two then shift into second and still makes a clanck when it goes into second gear.This is the only problem with the trans.All other gears work fine.The transmo has 135K miles on it and was ready for an overhaul anyway.So I purchased a Borg-Warner World Class T-5 master rebuild kit, complete with synchronizers.I removed the trans and installed the rebuild kit.Oh shure sounds easy enough.12 hours later I was finished the rebuild.Everything went back together the way it came out.Also took the opportunity to replace the clutch kit and upgrade the clutch cable.I have rebuilt Borg-Warner Super T-10's (4 speeds) for my Z28 and had no problems with any of them.This T-5 though,is a whole new ball game.Top loaded shifter for one thing. ANY WAY MY PROBLEM AFTER THE REBUILD IS:THE TRANSMISSION STILL HAS THE SAME PROBLEM I DESCRIBED ABOVE WITH SECOND GEAR, ALLTHOUGH NOT AS BAD.Anyone out there with some T-5 rebuild experience that could tell me what I might have missed,and what to look for when i open it back up.Any help would be appreciated.Thanks 1995 5.0 GT owner. __________________ 1995/GT/5.0 Last edited by 95/GT/5.0; 12-18-2002 at 04:34 AM..

12-18-2002, 08:57 AM	#2
302 LX Eric or '331 LX Eric' Join Date: Jan 1999 Location: Columbus, Ohio Posts: 2,142	You may want to give D&D Performance or Hanlon Motorsports a call. Both are good people with tons of experience with T5's... Links: www.ddperformance.com www.hanlonmotorsports.com Hope this points you in the right direction. E __________________ 1991 5.0 LX Coupe - 40,750 miles 331 cu. in. / Tremec 3550 / BFG Drag Radials 12.22 @ 114.31 mph - w/1.89 60'

12-18-2002, 10:51 PM	#3
Conman Registered Member Join Date: Apr 2002 Location: Kingston, Ontario Posts: 351	did you properly shim the input bearing? how did the shift fork look? how about the inside of the 1-2 slider? __________________ '88 lx, Black on Black, check it out here Spent all my money on school, what a dumb mistake I'm old enough to know better, but still too young to care.

12-20-2002, 03:42 AM	#4
95/GT/5.0 Registered Member Join Date: Dec 2002 Location: Biloxi.Mississippi Posts: 49	Hey 302 LX Eric,Thanks for the help.That hanlonmotorsports.com site was a great help.They have told me what to look for and have the parts I may need.That dnd site is cool too.I've had my eye on one of their rebuilt T-5's $849.00 for some time now but If all goes well I wont need it. I'm gonna take the damn thing out again next weekend at my brothers shop.It's not so bad when ya have air tools and a rack.It's just that damn top load shifter.Is there a trick to putting the cover with the forks lined up just right so the shifter works.It took me longer to get that right ,than it took to rebuild it.Maybe I'll ask the guy at hanlonmotorsports.Anyway I'll let ya know how it turns out.Thanks again. 1995/GT/5.0 __________________ 1995/GT/5.0 Last edited by 95/GT/5.0; 12-20-2002 at 11:33 AM..

12-20-2002, 03:58 AM	#5
95/GT/5.0 Registered Member Join Date: Dec 2002 Location: Biloxi.Mississippi Posts: 49	Conman, I did shim the front bearing,there was no visible sign of wear on any of the parts.Forks looked good,notch on shift levers looked good too.No metal in the case either.It was pretty clean for 135K miles.I'm gonna tear it down again after Christmas.Is there a trick to putting that top cover with the forks back on .That thing drove me crazy.I actualy got it right by accident after 100 tries.Last trans I rebuilt was a Borg-Warner super T-10 4speed and it had an external shifter.That cover just slaps back on.This top loader must be alien technology.Thanks for the help and if ya know anything about that cover re-installation please post again...1995/GT/5.0 __________________ 1995/GT/5.0 Last edited by 95/GT/5.0; 12-20-2002 at 03:25 PM..*

12-20-2002, 12:22 PM	#6
Conman Registered Member Join Date: Apr 2002 Location: Kingston, Ontario Posts: 351	I don't really remember any tricks because I just threw it on there first try. Maybe I got lucky, I don't know. make sure the sliders are in the neutral position and the forks are in the neutral position. You kinda have to lower it down and slide it at the same time. Be careful not to wreck your silicon bead though. __________________ '88 lx, Black on Black, check it out here Spent all my money on school, what a dumb mistake I'm old enough to know better, but still too young to care.

12-22-2002, 10:14 PM	#7
88workcar Registered Member Join Date: Oct 1999 Location: Pierre Part, La. U.S.A. Posts: 1,850	You need a 2nd gear and a 1-2 slider. The cover, if you have the tail facing you the cover must be lowered while being over to the right side about an inch an a half, once it is down, slide it to the left, right into place. Very easy. __________________ 88workcar 1988 Mustang LX 342. 417rwhp @ 6800. 28 X 10 ET Drag, 4.30s, 10.69 @ 126.43 1.42 60ft. 11.13 @ 127.7 on BFGs 1.72 60ft Rice Hater # 42 To be old and wise, You must first be young and stupid I'm somewhere in tthe middle.

12-24-2002, 01:17 PM	#8
95/GT/5.0 Registered Member Join Date: Dec 2002 Location: Biloxi.Mississippi Posts: 49	Hey 88workcar.Your the man.You was right about the slider,although the slider wasn't actually bad.It was the syncro keys (winged type) and the syncro spring that keeps the keys in place on the 1st,2nd & ,rev. slider (blocker) that are bad. I also found the blocker slightly off position on the shaft.Being that it is pressed on , it took a few wacks with a rubber malet to get it in the correct position.This couldn't have been helping the situation any.I'm waiting on the parts I ordered from hanlon motorsports.Very inexpensive parts, the keys and a spring..I have a better understanding of how this T-5 works now that I've had to pull it out again, and rip it apart,again!Knowing the sequence of operation helps too.This time I can run it thru the gears before I put the Top shift fork cover on.Thus making shure it goes into 2nd gear good this time. Shoulda done my homework the first time but ,I'll know better next time. I'll let ya know how it went in a week are so.Thanks 95/GT/5.0........................ __________________ 1995/GT/5.0 Last edited by 95/GT/5.0; 12-24-2002 at 02:17 PM..

12-26-2002, 05:02 PM	#9
95/GT/5.0 Registered Member Join Date: Dec 2002 Location: Biloxi.Mississippi Posts: 49	Update.Upon closer inspection I found the 1st,2nd gear slider bad too(a bit worn down).Got one ordered today $85.00 plus S&H $$$ spent on parts to date. World class master rebuild kit w/synchros$165.00,misc.small parts not included in kit $35.00,1st,2nd,gear slider $85.00 better than $1200.00 for a new one. 95/GT/5.0 __________________ 1995/GT/5.0

12-26-2002, 10:23 PM	#10
Conman Registered Member Join Date: Apr 2002 Location: Kingston, Ontario Posts: 351	glad you got it figured out and are fixing it I think being able to do the work yourself helps out huge on the pocket book. The only time my car has been in the shop is when I got new tires and free installation was included. Also I don't have a wheel balancer. Other than that everything gets done by me. __________________ '88 lx, Black on Black, check it out here Spent all my money on school, what a dumb mistake I'm old enough to know better, but still too young to care.

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