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I'm about 2/3rds of the way through the T5 swap on my 245 wagon. To be honest, i wouldn't be bothering with all the added hassle (vs. just replaing the trans with another Volvo trans) if I was keeping to rational boost levels and not shredding stock Volvo transmissions.
Q: Can I use a standard volvo pilot bearing?
A: No, the snout on a V8 mustang trans is larger. I think you can use a stock Ford pilot bearing, VPD supplies one that he says fits better. And look over any trans you buy carefully, I bought what was advertised as a '92 5.0 trans, and it turned out to be a 94-95 trans, which has a 3/4 inch longer input shaft. Took $120 more in parts (input shaft, input bearing retainer) to rectify that situation.
Q: Does the cross member need a lot of modification?
A: Modifications of some sort need to be made. The T5 just has two rather wide set vertical bolt holes at the rear end of the casing. The stock Ford trans mount extends straight downward to bolt to a horizontal area on a Ford crossmember. Doesn't mesh well with Volvo's concept of a forward leaning mount that counteracts the rearward lean of the motor mounts (to sort of cup the drivetrain between mounts). I'm just to that part of the project on mine, mulling over options.
Q: Does the driveshaft need to be cut?
Q: rear trans.flange?
A: Yes. Well, modified anyhow. I'm not sure if the T5 is longer than an M41 or not. I'm replacing an M47 on my car, and the T5 is significantly longer. There is no rear flange on a T5 either, a slip yoke (technically part of the driveshaft, I guess) slides onto the tailshaft. The Volvo end of the driveshaft needs to be cut off and replaced with a Ford slip yoke. This is not shade tree mechanic stuff, take it to a professional drivetrain shop after installing the trans in your car and getting good measurements.
Q: What speedo cable?
A: No clue on that. My car has an electronic speedometer (based on a sensor in the diff). So I just got a speedometer hole plug from Steeda ($15) to seal up the hole. You might need to have a custom cable built to fit between the T5 and the Volvo speedometer. And even then, you might have an issue with the gearing of the speedometer drive. Really not sure, I'm glad I don't have to worry about that on my car.
I had to get a custom clutch disc made for mine. I have a 9" clutch, and there is no 9" Ford clutch. There are, however, stock Ford applications for 8.5 inch clutches, so you might have a cheaper option there.
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'63 PV544 rat rod, '93 Classic #1141 245 +t
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