swap
I installed a 85 302 in place of my 5.0 fi in my work truck. I didn't have too many troubles but you will have to change the timing chain cover to match the old style water pump if you are going to go with the cougar acc setup.
I also did the AOD swap on my cat, with advice from Mark. Here's the scoop!!!
The AOD swap wasn't to bad. There are some obstacles but they are easy to overcome. The biggest one is the crossmember, you will need a new one. The are available from windsor fox or from Mark Piechowski but beware they may not work with your current exhaust. I tried one from Mark and it would not clear my Hooker headers and pipes. I made one, it was a piece of cake. The rest is a bolt in really. First get a trans thats from an 89 or
newer 5.0 mustang, I've been told they have a better lube circut, improved clutches and the right lever to work with our shifters. You will need the trans, converter, block plate & inspection cover, and yoke. The trans bolts right up. one of the trans lines from an FMX lines up perfect but the other is way off. I picked up a set out of the boneyard from a newer style tbird and cut the ends off by the radiator and installed a cooler with hoses conecting it. I didn't hook up my radiator cooler because it had been unhooked for years and I figured it was dirty inside. (I had a 4sp in there but it was a factory FMX car) Working your way back the next situation I came across was the starter nose, it fits but the top hole will be threaded on the trans and the starter, I drilled the threads out
of the starter and used it with no problems. Next thing to hook up is the drive shaft mine worked but I had already changed the yoke for the 4 sp swap, the AOD and 4sp yokes have the same splines. The FMX is different. There is some consideration on the speedometer. The AOD uses an electronic speedo that comes right out and your stock one fits the hole but the teeth on the gear is wrong. I went to the ford dealer and picked up a 21 tooth
speedo gear for six bucks to fit a 5.0 mustang and no problems. I am told that if you have a choice to get a trans that comes out of a mustang with 3:23 or lower rear end gears because the use a different gear on the trans shaft (7 or 8 teeth are the choices) thats not replacable without a complete teardown of the trans and a replacment shaft. The next thing to tackle is the shift nkage. Before installing the trans you need to pull the selector shaft out and rotate it 180 degrees. I was told that my stack
linkage rod would work but when I went to install it it was too short. The thing is I'm not sure that I was trying my stock one or one from another vehicle that was laying around the garage...duh I didn't put it in a safe place when I removed my FMX. Anyway it works out that I have park where its supposed to be and low in the trans shows 2nd on the shifter but it doesn't create a problem and looks stock. One more easy project, the
throttle cable. I picked up a lokar cable from a speed shop for 69.95, it was a piece of cake to install but I messed with the adjustment for a while after I started driving the car to get it the way I wanted it. The only other thing I did was install a shift kit and a drain plug on the pan. I'm even using the stock converter. I used the bauman shift kit and it was easy to install. The car runs great and getts a whopping 14 MPG on the highway.........lol Of course I am running alot of cam and 3:73's and my motor would prefer a set of 4:11's. The only downside I can speak of is the inherent quality of an AOD to be clunky for the lack of a better term when goin into OD. This is magnified in my car due to the cam, when it hits OD under part throttle it drops the engine below its power band and it luggs. Under moderate acceleration its not noticable and your results may be different. I have never had my car fast enough for a full throttle AOD shift but it chirps when it hit drive a full throttle, thats probably around the 60-70mph range. If you have any questions don't hesitate to ask, I'll be glad to help you or take pic of mine. Heres a couple sites to check out.
http://www.baumannengineering.com/aboutbe.htm
http://www.windsor-fox.com/
Good Luck
John