1987 Ford Mustang GT Manual Transmission Swap

The 1987 Ford Mustang GT manual transmission swap involves replacing the factory automatic transmission with a manual gearbox for improved performance and driving engagement. This comprehensive guide covers the entire process including parts selection, removal of the automatic transmission, installation of the manual transmission, clutch system setup, hydraulic connections, and final adjustments. Below are key sections for planning, parts, installation, and troubleshooting.

Planning and Preparation

Proper planning is essential for a successful manual transmission swap. Assess your mechanical skills and available workspace before beginning.

Required Parts and Tools

Gather all necessary components before starting the swap procedure.

• Transmission: T5 manual transmission (recommended for 5.0L V8)
• Clutch Kit: Complete clutch kit with pressure plate and disc
• Flywheel: 157-tooth flywheel for 5.0L engine
• Pedal Assembly: Manual transmission pedal set
• Master Cylinder: Clutch master cylinder and lines
• Slave Cylinder: Hydraulic clutch slave cylinder
• Shifter: Manual transmission shifter assembly
• Driveshaft: Manual transmission compatible driveshaft

Automatic Transmission Removal

Carefully remove the factory automatic transmission following these steps.

1. Disconnect battery and drain transmission fluid
2. Remove driveshaft and exhaust components as needed
3. Disconnect transmission cooler lines and electrical connectors
4. Support transmission with jack and remove crossmember
5. Remove torque converter bolts and transmission bolts
6. Carefully lower transmission from vehicle

WARNING! Transmission is heavy; use proper lifting equipment and assistance.

Manual Transmission Installation

Install the manual transmission following proper alignment procedures.

1. Install flywheel and torque to specification (75-85 ft-lbs)
2. Mount clutch assembly and align with clutch alignment tool
3. Install pilot bearing in crankshaft
4. Lubricate input shaft splines with high-temperature grease
5. Carefully guide transmission into position
6. Secure transmission bolts and install crossmember

CAUTION! Ensure proper clutch alignment to prevent damage.

Clutch System Setup

Proper clutch installation is critical for smooth operation.

Hydraulic Connections

Install and bleed the hydraulic clutch system.

1. Install clutch master cylinder in engine bay
2. Mount slave cylinder on transmission bellhousing
3. Connect hydraulic line between master and slave cylinders
4. Bleed system to remove air bubbles
5. Adjust clutch pedal free play (1/2 to 1 inch)

Tip: Use DOT 3 or DOT 4 brake fluid for hydraulic system.

Shifter Installation

Install the manual transmission shifter assembly.

1. Position shifter in transmission opening
2. Secure with mounting bolts
3. Install shift boot and console components
4. Test shifter movement through all gears
5. Adjust shift linkage if necessary

Final Adjustments

Complete final adjustments before test drive.

• Check transmission fluid level (GL-4 or GL-5)
• Adjust clutch pedal height and free play
• Verify reverse light switch operation
• Check driveshaft installation and U-joints
• Inspect all bolts for proper torque

Testing and Break-in

Proper break-in procedure ensures long component life.

1. Start engine with clutch depressed
2. Test clutch engagement in neutral
3. Make initial test drive in low-traffic area
4. Allow 500 miles for clutch break-in
5. Avoid aggressive shifting during break-in period

WARNING! Test in safe area; be prepared for unexpected behavior.

Common Issues

Be aware of potential problems during and after installation.

Troubleshooting

Professional Help: Consult experienced mechanic for complex issues.

Resources: Mustang forums and factory service manuals recommended.