Problems Installing T45

Rich2279 · January 3rd, 2012, 10:29 PM

Well, I installed the '03 Explorer aluminum 4.6L in my '98. Slid right into place. Problem is with the T45 trans. I can not get it to slide in there. Spending way too much time on this. I am at the point where I'm considering pulling the motor back out, attaching the trans, and then installing them together. Anyone have ideas? I've been fighting this trans the past 3 days (few hours each day) trying to slide it in.

war1ock · January 3rd, 2012, 10:56 PM

Im assuming its going into a already manual car not an original automatic? Do you mean like you just cant get it into the right placement to bolt it up? Maybe try taking the crossmember out. Wouldnt see what would cause the problem.

Rich2279 · January 4th, 2012, 10:56 AM

Originally Posted by war1ock

Im assuming its going into a already manual car not an original automatic? Do you mean like you just cant get it into the right placement to bolt it up? Maybe try taking the crossmember out. Wouldnt see what would cause the problem.

Yes, my car always was a 5 speed. The Explorer was an auto (of course). Crossmember is out and the engine is tilted back. I just can get the spline on the output shaft to slide all the way in. I was thinking maybe the two dowels/guides in the '03 block are slightly larger and maybe that is a reason, but I doubt it.

BMR Tech · January 4th, 2012, 10:58 AM

Polish the dowels with a dremel.

Polish the inside of the dowel opening on the bell.

Ensure there is nothing between the block/bell (wiring)

Slide the trans forward....if it doesnt want to go in...turn the crankshaft a little until it pops in.

c-for · January 4th, 2012, 12:39 PM

it could be that in 2003 the 4.6 with a 5 speed was not a t45 but was a t3650 so the input shaft size could be differant

Rich2279 · January 4th, 2012, 01:28 PM

Originally Posted by c-for

it could be that in 2003 the 4.6 with a 5 speed was not a t45 but was a t3650 so the input shaft size could be differant

You mean the length of the output shaft? The clutch is from a '98 and is 10 spline. The plastic clutch tool slides in w/no problem. I would think that if a t45 does not work with a new engine, that would have come up when I did a search, but you never know.

zdkel · January 4th, 2012, 06:52 PM

DId you install a new pilot bushing? The trans input shaft has to fit into that (thinking out loud).

Rich2279 · January 4th, 2012, 10:45 PM

Originally Posted by zdkel

DId you install a new pilot bushing? The trans input shaft has to fit into that (thinking out loud).

Yes, a new roller bearing type. Now, I need to replace one of the dowel pins, but it is seized in the block. Heat and PB blast has not helped the situation.

BMR Tech · January 5th, 2012, 09:35 AM

Knock it out form the front side..

Rich2279 · January 5th, 2012, 10:54 AM

Originally Posted by BMR Tech

Knock it out form the front side..

Yes, I'm going to try that tonight if I can get something in there. Kind of difficult with the exhaust manifold on and w/ the engine in the car. I'll also try putting a tight fitting socket on it and wiggling it out.

sj408 · January 5th, 2012, 01:19 PM

Originally Posted by Rich2279

I've been fighting this trans the past 3 days (few hours each day) trying to slide it in.

Try to take her to dinner i hear the trannys like to be wined and dined

sorry i had to

sj408 · January 5th, 2012, 01:27 PM

double

Rich2279 · January 5th, 2012, 03:35 PM

Originally Posted by sj408

Try to take her to dinner i hear the trannys like to be wined and dined

sorry i had to

LOL, no harm done. As much as a pain the tranny is, it will be worth it.

January 3rd, 2012, 10:29 PM	#1
Rich2279 Regular '92 5.0 & '98 Mustang GT Join Date: Aug 2011 Location: New Jersey Posts: 99 iTrader: 1 reviews	Problems Installing T45 Well, I installed the '03 Explorer aluminum 4.6L in my '98. Slid right into place. Problem is with the T45 trans. I can not get it to slide in there. Spending way too much time on this. I am at the point where I'm considering pulling the motor back out, attaching the trans, and then installing them together. Anyone have ideas? I've been fighting this trans the past 3 days (few hours each day) trying to slide it in. __________________ *'98 Mustang GT* *'92 Mustang LX 5.0L* *'11 Ford Focus SE* http://www.cardomain.com/ride/394916...ng-gt-coupe-2d

January 4th, 2012, 10:58 AM	#4
BMR Tech Authorized Vendor Join Date: Feb 2009 Posts: 748 iTrader: 0 reviews	Polish the dowels with a dremel. Polish the inside of the dowel opening on the bell. Ensure there is nothing between the block/bell (wiring) Slide the trans forward....if it doesnt want to go in...turn the crankshaft a little until it pops in. __________________ Kelly Aiken "The Ford Guy" BMR Suspension Inc kelly@bmrsuspension.com 813.986.9302 CLICK IF YOU LIKE BMR SUSPENSION

January 4th, 2012, 06:52 PM	#7
zdkel Regular 1996 Mustang GT Join Date: Jun 2009 Location: Riverview, Fl Posts: 372 Blog Entries: 2 iTrader: 0 reviews	DId you install a new pilot bushing? The trans input shaft has to fit into that (thinking out loud). __________________ 96 GT - PI Intake & cams, O/R h-pipe, Flowmasters - 40s, Short Throw Shifter, 3.73 FRPP gears.

January 5th, 2012, 09:35 AM	#9
BMR Tech Authorized Vendor Join Date: Feb 2009 Posts: 748 iTrader: 0 reviews	Knock it out form the front side.. __________________ Kelly Aiken "The Ford Guy" BMR Suspension Inc kelly@bmrsuspension.com 813.986.9302 CLICK IF YOU LIKE BMR SUSPENSION

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January 4th, 2012, 12:39 PM	#5
c-for Newbie 1998 mustang gt Join Date: Mar 2011 Location: nashville, nc Posts: 12 iTrader: 0 reviews	it could be that in 2003 the 4.6 with a 5 speed was not a t45 but was a t3650 so the input shaft size could be differant

January 5th, 2012, 01:27 PM	#12
sj408 Hardcore Enthusiast Join Date: Jul 2010 Posts: 2,055 iTrader: 0 reviews	double

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