Re: Installing a T5 in a classic Ford, other than a Mustang
Just did this swap twice last summer with a 97 3.8L T5 in my 65 Falcon sedan and my 66 Mustang coupe. Here's what I found out during the swap.
I you want the mechanical speedo you'll need a pre-96 tailshaft housing. I used a 93 which required some creative grinding as the later T5's had an "oil slinger" added to the od gears that the housing is machined for. The earlier tail housings don't have it but some time with a grinder solved that.
The 3.8 bell can be used with the correct starter and a 164 tooth flywheel as mentioned, but the 3.8 flywheel will not work. It is a 0 balance and will vibrate the 302 badly. You need to find a flywheel with the proper balance for your engine year. The 3.8 T5 will bolt up to a 94/95 V8 bell (hard to find) and allows the standard (in most cases) 157 tooth flywheel. I used the 5.0 bell in the stang & 3.8 bell in the falcon. The flywheel also dictates the clutch to a degree. I used a late model diaphragm clutch in both cases so I had to find a flywheel that had that clutch type bolt pattern. The 157T flywheel was easy, the 164T I would up using a flywheel from a 64 Galaxie with a 289. Don't remember the part number off hand.
I went hydraulic setup in both cars. I know the fork comes out lower in the bell which gave me extra space in the Falcon. That engine compartment is 1" narrower than the Stang so header space is at a premium. I used a external slave cylinder on a home made bracket to actuate the clutch (no one produces one for this T5 application) . Went internal on the Stang, so no fork at all (kinda leary on that one after some stories I've heard about leaks).
The Falcon required some floor pan surgery to keep the driveline angles correct. I pie cut the tunnel and extended the floor to raise the tail of the trans. Wound up cutting into the cross brace and "re-designing" that while I was there.
Too many things to finish on the Stang so I can't say how it works just yet. The Falcon drives beautifully and I get around 23mpg on the highway if I can keep my foot out of it... Only thing is I tore her down again to add EPAS and swap in 06 Mustang bucket seats and a homemade console.