D24T Rebuild and T5 Swap
 

I decided to make a thread to track the progress of my engine rebuild and T5 WC swap. I had been posting pictures here and there, as well as asking a few questions, but wanted to put it all in one place.

So far I have rebuilt the engine, but not fired it up yet. I have been focusing on getting the transmission setup for the D24T and 1983 760. I am very close. I had a custom brass pilot bushing made, I have the custom clutch disk, and I have been working on moving the shifter mount a little further back (pictures below). My plan is to bolt the engine and transmission together, and put them both in the car at once. At that point I will be able to take one final measurement of the length required for the driveshaft, and take it to the machine shop to have it completed. While the driveshaft is gone, I will use that time to hook all the odds and ends up in the car, as well as add the clutch pedal assembly.

I also bought an intercooler and boost gauge to add once I get the major parts back in.


Spenser

Looks good. So the shifter on the gm t5 still had to be moved back huh?

Yeah it had to be moved back, and by the looks of the pictures from the t5 swap sticky, I would guess its the exact same as the ford t5. The automatic trans was still in the car, so I measured from the bell housing back to the center of the shifter hole (32.5"). I then measured from the bell housing back to where the shifter needed to be on the t5, and that's how I figured out what dimensions to make my aluminum plate.

I finished fabricating the actual linkage today. The original piece that received the shifter was a strange alloy, and did not like to be welded to. I ended up brazing a steel rod on the end of it and then welding a 5/8" socket on the end of that. Works well (stole that entire idea from the t5 swap sticky). Tomorrow I will probably be modifying the clutch fork slightly to better fit the mustang throwout bearing.

I finally got the engine and trans in today.

Looks good, and the next step will be to fabricate a transmission mount and get the driveshaft shortened to the right length.

Sturdy looking engine hoist!

Thanks!

I dropped the drive shaft off at the shop. I also made the transmission mount.

While the driveshaft is gone I will be hooking up the clutch cable and installing the clutch pedal/ new brake pedal, as well as hooking up as many other odds and ends that I can.

I got the clutch pedal and cable installed, as well as the shifter. It all seems to work pretty good. Still waiting on the drive shaft... But I also installed the turbo today and got the buss bars on the glow plugs. Filled it with oil also, after installing the dipstick too.

Just out of curiosity: what condition was the front crossmember in? Your photo there reminded me that mine and a few others had bad cracks and separations.

Seems to be OK. I cleaned it up before installing the engine, and I didn't notice any cracks.

I put the driveshaft on today. Seems to fit very well. I also put the car back on the ground (it was sitting up on 12" blocks to make it easier to work on).

Not much else to do but put the intake together and give it a cooling system, then I can fire it up. I'm still deciding if I want to take the time and intercool it now, or wait until its going... I'm leaning towards doing it now.

Spenser