Thinking about ditching the automatic in your 2000 Ford Mustang for a more engaging manual driving experience? You’re in the right place. Many Mustang enthusiasts find the control and feel of a manual transmission far superior, and converting your SN95 Mustang is a rewarding DIY project. This guide, based on real-world experience, will walk you through the essential parts and steps needed to perform a successful automatic to manual transmission swap on your 1999-2000 Ford Mustang. You might be surprised to learn it’s more straightforward than you think, and you won’t even need to program a new ECU!
Essential Parts for Your Manual Swap
Before you get started, gathering all the necessary components is crucial. Sourcing parts from a junkyard is a budget-friendly approach, but ensure you inspect everything for wear and tear. Here’s a comprehensive list of what you’ll need for your 2000 Ford Mustang manual transmission conversion:
- Pedal Assembly: This is essential for adding the clutch pedal. You’ll need the complete assembly including the clutch pedal, brake pedal (manual brake pedal is narrower), and associated hardware.
- Driveshaft Yoke (Transmission Side): The automatic and manual transmissions use different yokes. You’ll need the yoke that mates with the manual transmission. Sometimes it’s easier to grab the whole driveshaft from the manual transmission car.
- Manual Transmission: A T-5 transmission is a common and compatible choice for 2000 Ford Mustangs. Confirm the specific type using this guide to T-5 Identification to ensure it matches your engine and application.
- Clutch Cable: This cable connects the clutch pedal to the transmission’s clutch fork.
- Shift Boot and Rubber Under-Boot: These interior pieces provide a finished look to your manual shifter setup inside the cabin.
- New Clutch Kit: A new clutch is highly recommended while you have everything apart. Brands like LUK are known for their quality and affordability.
- New Flywheel: Similarly, a new flywheel is a smart investment. SACHS is a reputable brand.
- Flywheel and Clutch Bolts: Crucially, use bolts specifically designed for a manual transmission flywheel and clutch. Automatic transmission bolts are typically not long enough and can lead to failure. Refer to your Mustang repair manual for the correct specifications.
Step-by-Step Guide to Your Manual Transmission Swap
This guide assumes you have a basic understanding of automotive mechanics. If you’re unsure about any step, it’s always best to consult a more experienced mechanic or a detailed repair manual specific to your 2000 Ford Mustang. Safety first! Always use jack stands when working under your car and disconnect the battery before working on electrical components.
1. Pedal Assembly Removal:
- Access: Begin by accessing the pedal assembly area under the dashboard.
- Disconnect Clutch Cable (Automatic): Locate and disconnect the automatic transmission’s clutch cable (if applicable) from the pedal assembly.
- Steering Column: To gain better access, you may need to loosen or partially disconnect the steering column. In the donor car, four nuts attaching the pedal assembly directly to the brake booster and one screw at the top will need to be removed. In the junkyard, it might be faster to remove four steering column nuts and use a pry bar to bend the fuse box upwards for clearance.
- Remove Pedal Assembly: Carefully remove the four nuts and top screw holding the pedal assembly. Remember to detach the clutch cable from the pedal assembly before fully removing it.
2. Clutch Cable Removal:
- Detach from Transmission: Disconnect the clutch cable from the automatic transmission.
- Remove Cable Assembly: Take the clutch cable completely out of the car. Retain the self-tapping screws as you’ll need them for installing the new manual clutch cable.
3. Manual Shifter Installation:
- Remove Automatic Shifter: Remove the automatic shifter assembly from inside the car.
- Install Manual Shifter Components: Install the shift boot and the rubber seal/insulator that sits below it. Attach the top half of the manual shifter to the transmission.
4. Automatic Transmission Removal:
- Disconnect Components: Before unbolting the transmission, ensure you disconnect all wiring harnesses, cooler lines, and the speedometer cable connected to the automatic transmission.
- Exhaust Removal: Unbolt and remove the exhaust system. Don’t forget to disconnect all oxygen (O2) sensors before exhaust removal.
- Driveshaft Disconnection: Disconnect the driveshaft from the rear axle and slide it out from the transmission.
- Transmission Mount Bolts: Remove the bolts securing the transmission mount to the chassis.
- Bell Housing Bolts: Support the transmission with a transmission jack. Access and remove the lower bell housing bolts first, along with the starter motor. Removing the transmission mount bolts before the top bell housing bolts makes reaching the upper bolts significantly easier.
- Torque Converter Bolts: Crucially, before fully removing the transmission, access and remove the torque converter bolts that connect it to the engine’s flexplate.
- Transmission Removal: Carefully lower and remove the automatic transmission.
5. Manual Transmission Installation:
- Flywheel and Clutch Installation: Install the new flywheel using the correct flywheel bolts for a manual transmission (automatic bolts are too short!). Then, install the new clutch kit and pressure plate, ensuring proper alignment.
- Throw Out Bearing Installation: Install the new throw-out bearing onto the input shaft of the manual transmission.
- Transmission Mounting: Check the dowel pins on both the engine block and the manual transmission bell housing to ensure they are present and aligned. Carefully lift and slide the manual transmission into place, aligning it with the engine.
- Bell Housing Bolts: Install and torque the bell housing bolts to the specified torque.
- Starter Installation: Reinstall the starter motor.
- Transmission Mount Installation: Reinstall the transmission mount and tighten the bolts.
- Clutch Cable Connection: Route and connect the new clutch cable. Secure it to the firewall using the self-tapping screws you saved earlier. Connect the other end of the cable to the clutch fork on the transmission and to the pedal assembly inside the car.
6. Wiring and Final Steps:
- Automatic Wiring Harness: Since you are keeping the original ECU, you’ll need to bypass the automatic transmission sensor inputs to avoid a constant check engine light. Locate the black box on the driver’s side of the automatic transmission harness and detach it. Connect it back into its harness. You’ll notice a white circle in the middle of this detached box – this is a rotary sensor. Manually rotate this white circle until the notch on it aligns with the “neutral” notch on the box housing. Secure the box in this “neutral” position with zip ties and tuck it away safely. This fools the ECU into thinking the transmission is always in neutral, preventing error codes related to missing automatic transmission sensors.
- Manual Transmission Wiring: There’s typically another connector on the manual transmission (often for reverse lights and potentially a neutral safety switch). Plug this connector into the corresponding connector on your Mustang’s wiring harness.
- Exhaust and O2 Sensors: Reinstall the exhaust system, remembering to reconnect all O2 sensors.
- Driveshaft Installation: Reinstall the driveshaft, connecting it to both the transmission yoke and the rear axle.
7. Final Checks and Break-in:
- Fluid Check: Fill the manual transmission with the correct type and amount of transmission fluid.
- Clutch Adjustment: Adjust the clutch cable to ensure proper clutch engagement and disengagement.
- Test Drive: Carefully test drive your Mustang, checking for smooth shifting and clutch operation.
- Clutch Break-in: Follow your clutch manufacturer’s recommendations for break-in. A common recommendation is to drive conservatively for the first 500-1000 miles before engaging in aggressive driving or performance applications.
Conclusion
Converting your 2000 Ford Mustang to a manual transmission is a significant but achievable upgrade. By carefully following these steps and ensuring you have all the necessary parts, you can transform your Mustang’s driving dynamics and enjoy a more connected and engaging driving experience. Remember to prioritize safety, double-check your work, and enjoy the enhanced control of your newly manual Mustang!
