Winter Project - Rebuilding a Borg Warner T5 Transmission

[Lugnutz65]

My winter project is underway.
This will go in my 1965 SWB Stepside. This T5 is a hybrid. It will have V8 Camaro gears, Camaro input shaft and case. That way I do not need to use an adapter plate. It's a Hybrid because I will combine it with an S10 case cover and tail housing with the cable speedo drive. I will use the factory S10 main shaft so the drive gear for the speedo is in the right location for the S10 tail housing. You can see more on my website.

[Bullett]

Wow, you have more courage than I have.

[Lugnutz65]

Originally Posted by Bullett

Wow, you have more courage than I have.

No courage here. Just too cheap to buy one already done. Besides, I love learning how to do stuff like this.

[Bullett]

Originally Posted by Lugnutz65

No courage here. Just too cheap to buy one already done. Besides, I love learning how to do stuff like this.

I hear ya, I like learning new stuff also. Just always never quite dared to attempt a tranny. I wouldn't think there would be much room for error.

[Sharps40]

How come the camshaft speedogear difference
I thought use of the camero T5 in a bench seat truck only needed install of the S10 tailshaft cover. Was that internet myth too?

[Sharps40]

I got it. Tailshaft is back half of mainshaft/comes with s10 cover?

[brokenspoke]

Looking forward to this ..subscribed

[Mackie]

Nice clean work Lugz! Everything laid out like in an OR. If you have time left this winter can you build me one?

[Lugnutz65]

Originally Posted by Sharps40

How come the camshaft speedogear difference
I thought use of the camero T5 in a bench seat truck only needed install of the S10 tailshaft cover. Was that internet myth too?

Originally Posted by Sharps40

I got it. Tailshaft is back half of mainshaft/comes with s10 cover?

Sharps40,
Folks who swap the Camaro tail housing for an S10 tail housing also swap the cover plate so they have the correct length shifter mechanism. They also usually relocate the DRIVE GEAR so that is lines up with the DRIVEN GEAR location on the S10 tail housing. It is NOT hard to relocate the DRIVE GEAR. It is well explained on this Inliners.org web page. You have to click the Tech Tips on the side bar and then The T5 Tranny Page on the Inliners Tech Page. Go to the bottom of the T5 Page and you will see Camaro T5 Hybrid. (Sorry, but that's the only way I can navigate you there.)

These photos show how my choosing to use the S10 main shaft saved me the extra work and I don't need to do the shim mod described in the Inliners article.

[Lugnutz65]

Just a few more pics to add. More on my website. I got all the bearings and seals pressed in tonight. Assembly of the rest of it tomorrow. This is the most fun project I've done to date.







Pressed the tapered roller bearing onto the input shaft.





Pressed 5th gear into place.





Tail Housing Seal

[Sharps40]

Sharps40,
Folks who swap the Camaro tail housing for an S10 tail housing also swap the cover plate so they have the correct length shifter mechanism. They also usually relocate the DRIVE GEAR so that is lines up with the DRIVEN GEAR location on the S10 tail housing. It is NOT hard to relocate the DRIVE GEAR. It is well explained on this Inliners.org web page. You have to click the Tech Tips on the side bar and then The T5 Tranny Page on the Inliners Tech Page. Go to the bottom of the T5 Page and you will see Camaro T5 Hybrid. (Sorry, but that's the only way I can navigate you there.)



Got it more shimming and modifications out back on the Camaro trans. Okay...looks like its all pretty easy.

[Sharps40]

How do I get the speedo housing to seal. It don'l leak where its gooed but it does leak out around the speedo cable housing flange. I'm thinkin a felt gasket tween the flange and the flange nut to take up the slop.

[Lugnutz65]

Originally Posted by Sharps40

How do I get the speedo housing to seal. It don'l leak where its gooed but it does leak out around the speedo cable housing flange. I'm thinkin a felt gasket tween the flange and the flange nut to take up the slop.

I haven't gotten that far yet, so I really don't know the answer. But your idea using felt sounds like it might work.

[Bullett]

This thread is awesome, thanks for sharing it.

[Sharps40]

Originally Posted by Lugnutz65

I haven't gotten that far yet, so I really don't know the answer. But your idea using felt sounds like it might work.

We installed the bullet with new seal, leaks.....added Blu Goo, leaks out between the bullet and the coupling.

So, since the bell on the end of the speedo cable wobbles in the coupling nut I figured maybe to felt washer it front and back to seal it up.

[Lugnutz65]

Originally Posted by Bullett

This thread is awesome, thanks for sharing it.

I'm glad you like it. I'm posting this project with the hope that it will encourage other novices like me to tackle projects that seem daunting. I've dreamed of doing this for about a year. IF I CAN DO IT, YOU CAN TOO. I'm not a rocket scientist.

Countless others on this site have inspired me to tackle stuff I would have never dreamed of doing, and they were there to help me when I ran into a snag or had a question. So I have to say a BIG THANK YOU to the members of this forum.

And now for the FINALE'. Drum Roll Please!!!!!!

More photos and details are on my website.

Reverse gear is in.



Main shaft is in.



Input shaft is ready to install.





Input shaft bearing retainer holds it all in place.



5th gear slider goes on.



Lock on the 5th gear slider with a washer and snap ring.



Oil funnel, bearing and race go on the countershaft before installing the tail housing.



I started with all this stuff and a rebuild kit.



And now I have this.



And this too of course. A customized and freshly rebuilt V8 Camaro NWC T5 with a 2.95 1st gear and a 0.73 5th gear. It has the S10 tail housing and case cover so it will work with the bench seat in my 1965 C10 SWB Stepside with a 250ci and 3.73 rear diff.

[Sharps40]

Lugnutz. I think I have the answer on the leaky T5 speedo gear bullet.

There is an outer O ring to seal between the case and the bullet and prevent drips......the place where most add Goo....

There is an inner driven gear shaft seal to keep the oil from wicking out along the shaft to the cable and dripping.

I ordered a new bullet from the gearbox. $6.95 and $5 shipping.

Now, I still expect to have the slop between the speedo cable nut and the cupshaped lip of the housing flang....so, I'll make a nice felt washer to go tween it and bullet, fitting up inside the screw on cap. That should help with any wicking and still remain flexible enough to allow the cable to self center in the bullet/cap assembly.

If that don't seal it up....I'm gonna weld the hole shut and go to GPS speedometer.

[Lugnutz65]

Here is my bullet and driven gear for comparison.

[Sharps40]

Looks close to mine in length but totally different in shape. I ordered another one like the one I have. Mine has a smooth/un-indented cone where it abuts the gear. Like a very simple sharpened pencil point. Once the new one comes in I'll check both. From pics, the inner seal for the driven shaft appears to me to be installed in the cone end, where the cone abuts the gear head.