sugarsn10

iTrader: (2)

So this is a project I've been working on for a solid 2.5 months on this project for one of my senior classes. I just recently was able to create the first part and it came out surprisingly well. The basic idea of the project was based on the theory that the primary weakness of Borg-Warner T-5 transmissions is the lack of rigidity in the case. Therefore, I set out to produce a T-5 main case from ductile iron. After the semester is over I plan on doing a thorough write-up on the process. For now, I just want to share a few pictures of the project and first piece just to show what I ended up with. Let me know what you guys think of the project. I know lots of people are pretty down on T-5's all together and probably think it was a waste of time, but others may find it an interesting way to make T-5's more useful.

sugarsn10

iTrader: (2)

The first couple pictures were taking while making the mold. The others are of the part fresh out of the mold with the gating and risering still attached. And the last couple are of the part after is had some initial grinding and shot blasting done. Still a long ways to go to make it a working case, but that's for next semester.

sugarsn10

iTrader: (2)

Gumby

youll find the T5 gets allot more love on the truck boards, they put them in all the time, are glad 3rd gen guys dont want em.

sugarsn10

iTrader: (2)

Ya, that makes sense. I know a lot of guys on here like to go the t-56 or tko route, but I figured there's a couple of guys interested around here. I have just always been curious about figuring out another option that would be more affordable than going the t-56 or tko option. My time isn't worth much while I'm in school so now is the time to mess around with the idea.

I know that another weakness they talk about is the distance between gear sets is not ideal compared to other transmissions, which this project does not fix. It does however eliminate the problem of having a weak case, which to me would put the transmission into classification. Why would you want anything to do with a transmission whose main member is overloaded even at stock power. So my next question is, with stock gear sets in an iron case, how well will it fare? Are the stock gear sets also over powered slightly above stock power?

The other reason I've been unwilling to settle for the T-56 is weight issue. While this case is much heavier than the aluminum one, the entire transmission will still be considerably lighter than the T-56.

Gumby

problem comes down to driver, long time ago I did a fluid thread poll, had people using ATF, 80-90, 80-90/ATF mix, 30w oil.....

Thing I found was those that had uo to built 400s and were racing every weekend on a T5, changed the fluid every other oil change. [ didn't matter which kind]

But then ya got guys with bone stock 2bb 305s that blow the guts out every block.

If ya speed shift, or abuse them, they fail, drive em right they can hold up to allot.

sugarsn10

iTrader: (2)

Ya, I've also heard before it has a lot to do with with the driver. It still means they have a weakness. You don't hear many people saying that the only way a T-56 will stay together is through proper driving. It's nice to have the insurance knowing that even if you beat on it, it will stay together.

InfernalVortex

iTrader: (4)

Sometimes I wish I had a T5. For my usage I dont think I would blow one up ayn time soon and it'd take ~50lbs out of the car for the autocross stuff.

But my headers/exhaust wouldnt fit it, so meh.

sugarsn10

iTrader: (2)

Ya, I definitely agree that weight is the main advantage the t-5 has over the t56. I think if there is a way to make it stronger more easily, it would be a more viable option for many.

OrangeBird

iTrader: (1)

You are taking something you like , and attempting to improve it . This is the true Engineer spirit and I for one greatly admire your attitude of "like what's to like and fix everything else" rather than just jumping on the T56 bandwagon . Admittedly , casting one's own transmission case is something that not many folks are able to do and thereby justifies the T56 choice for many , Still I think it's just about downright awesome to see how one bright soul went about bringing some love back to the T5 .

GREAT WORK !!!!!

90camaro355rs

well said, I am a T-5 user and would love to see how this turns out. please keep us posted!

sugarsn10

iTrader: (2)

init4fun and 90camaro355rs, thanks for the encouragement and interest in the project. I truly believe that it is much more interesting to try to create a solution to the problem instead of replacing the product altogether. I agree most people don't have the opportunity to cast their own parts, but with the program I'm in, I have this somewhat rare opportunity. After the mess of finals week calms down, I'm going to go much more in depth of how it was done. The next step in the process is going to be machining it. This is what I'm much more worried about and unsure of how it will go.

Bullydawg

iTrader: (7)

Subscribed to see how it ends up... I am one of those T56 guys. Although if the T5 would have held the power and been more affordable, I would have gone that route!

HankL69

iTrader: (1)

x2

Bow_Tied

iTrader: (1)

awesome!

robertfrank

iTrader: (27)

Subscribed....awesome idea. If this comes to fruition mark me down for one

T5Lugnutz

As a T5 enthusiast from one of the Chevy truck forums, I'm giving this 2 thumbs up. The results look nice. Keep up the good work. There are a lot of folks out there who want a S10 tail housing with the cable connection. Just saying that the demand for the tail housing might make it a worthwhile project to consider as well. The used ones (cable connection) sell for around $200 each on eBay.