Documentation on Converting your Alpine with a 2.8 V6 FORD Engine

By DanR

Last Update: 12/1/2018

I have created this bit of documentation for those of you that are wanting more power and maybe cruising the Highways at modern speeds. Even perhaps cooling your trips with an Air Conditioner or perchance Electric Power Steering (EPS) like I have done. My suggestion for the best and perhaps most economical way is by installing a FORD 2.8 V6 engine in an Alpine. This documentation is in no way complete, but, a lot better than what I had to start with.

The Ford 60 degree V6 engines referenced here were designed in Cologne Germany and became known as a Cologne engine. Just remember the The Cologne engine is all metric. We will likewise be working with the 1974 & 78 Mustang II and other interchangeables such as the Pinto, Mercury Capri and Mercury BobCats and the 1983-86 Ranger/Bronco II’s and some Aerostars. I have found some ‘79 &’80 Mustang & Mercury Capri also have engines, flywheels and maybe bellhousing that are acceptable for this conversion. The early 2.8’s are common with the other 60 degree 2.9 & 4.0’s except for one major characteristic, that being the Siamese exhaust ports on the 2.8’s. This design is said to be especially fitting for the Alpine conversion as an implant of the 2.8 V6 Power plant just because of the exhaust port design.

It seems to be a natural fit for the Alpine. Removal of the original engine mounts is the only necessity with exception of widening of the transmission tunnel in some cases, so you will not be butchering your Alpine.
Installation is made easy with the use of my two piece engine mounts consisting of: (1). a top bracket that is bolted to the engine; (2). The Anchor 2424 rubber biscuits connecting the top piece and (3). The bottom piece that serves as a “Stop or catch” on the crossmember which keeps the engine from being placed too far forward thus allowing adequate spacing between the radiator and the fan. This bottom piece is welded in place. See PIC below for the “Stop”. Details are furnished on the alignment, fitting and necessary welding for a nice complete installation of the engine mount brackets (See Engine Mounts).

In order to help you find various parts or find answers to some questions, this documentation is arranged in alphabetical order by components or individual pieces that may be utilized in the conversion.

ADAPTER, PILOT SHAFT BUSHING

Your transmission selection “will” determine whether or not you will need an adapter. For sure if you elect to go “Automatic” the adapter is not applicable. See PILOT Bearing.

AIR CLEANER

Various choices are available, here the 9” Spectre P/N 4770 is a nice choice on SD Pace’s 2.8 V6.

Notice He is running an A/C unit too. Top hose connect from the water neck on the intake routed to the top left of radiator is one such modification recommended for a better fit down below with the modified Thermostat housing. More on the recommended options later. Not shown is his Electric Power Steering (EPS). Smart Guy:)

AIR COMPRESSOR BRACKET

Consist of 2 pieces, comes with Adj arm. An option for you Guys & Gals wanting to have a “Cool”Alpine. PIC’s are available for How to do the A/C.

ALTERNATOR

I like the A/C Delco single wire mainly because it is available in about any parts store if you should need one while away from home. Another popular one is the Hitachi 14231 (Advance Auto) from a 1973 Datsun Truck.

ALTERNATOR BRACKET w/Adj Arm

2 piece allows for precise alignment of your alternator.  Below PIC shows Bracket in place w/bolts.

BATTERY CABLE

Solenoid to starter Standard A32-1L 1 gauge 32” long. Runs from starter solenoid on firewall to the starter.

BEARING RETAINER

The bearing retainer (Transmission Input Shaft) needs to be shortened to the length of the FORD 5.0 T5 (1994-95 V8 applications) which is 4”.

BEARING RETAINER/Housing

See also PILOT BEARING

RETAINER/Housing: Needs to be shortened to 4” (the length of the 5.0 T5). And the diameter needs to be milled to fit snugly in the opening of the Mutt II bell housing. The Bell housing ID is 4.850″ .  To mate with a slip fit, the Input Bearing Retainer Large diameter should be turned to 4.846″ +/- 0.001″. See PIC

BELL HOUSING

The correct bell housing P/N D4ZA-6394 CC: It’s made of aluminum & the most defining feature is the bell crank to operate the clutch, an arm/lever from the driver side of the bell housing.

The clutch lever is a must for the V6 conversion, unless you go with an internal hyd release bearing or convert to an Automatic transmission. The area in the “Orange” circle is where the stock clutch cable release connection was originally. It must be removed to provide clearance for an external slave cylinder to function.

CAM

What choice of cam to use will bring lots of opinions. I followed the flow when I first started my conversion! I bought a cam that was recommended as a mild to hot street only to find out later that it was a “Full Race” cam. Not good for what I wanted. If you want a “Hot”, “Big”, race cam Delta Cams has what you need. After about four months of trying to get my V6 to idle below 1300 – 1500 RPM (Zero Vacuum below 900-1000RPM) I gave up and called Delta. Quickly learned it was a “BIG CAM Full RAce with zero vacuum below 900 RPM”. COMP; Crane; ERSON and a few others can fix you up nicely.
Highly recommend a mild cam for street and everyday driving and maybe gettin’ it on occasion. If you want to race, Delta has it!

CARBURATION

You have several options. Run a stock setup 2bbl or a 4 bbl with OFY intake pictured below which is a very good performer. In 2nd PIC the stock water neck points to the right side of the Alpine. 3rd PIC shows both angles. In 1st PIC below the water neck has been modified to turn toward the left side of the radiator. I have until recently recommended modification to point to the left for a simpler connection and routing of the Hoses. Even though it is more expensive, it’s an effective modification that looks nice. But, In an attempt to be both performance minded and cost effective, I recently discovered perhaps a “better” way to route the upper water hose and save dollars! (See Radiator modifications for directions and a PIC of the new routing of the upper hose Gates 21341 cut to fit). Lots of good selections on the Custom Valve Covers too!

NOTE: Bolts for the valve covers to heads are 6mm 1.0 20

 

The original Ofy water neck on left and my modified on right). (See also “RADIATOR MODIFICATION”) Special note of caution, if you wish to add another connection to the Modified Water neck, I suggest it be at/in the top next to the current fitting.

In the PIC above a least expensive way to route the upper radiator hose, utilizing a stock (or Ofy) water neck with a Gates 21341 hose cut to fit and jointed together with a metal pipe.

Carburation Con’t

Installation of the OFY intake manifold requires some special attention. It is made in two pieces, a top for the Carb Base and the bottom that connects to the heads. The PIC’s that follow may be of great benefit to the installer. You will need four (4) Metric bolts one of which is shorter than the others. It is to be installed in the right rear recessed hole. In the lower PIC there is a rib that runs between the holes, notice the empty hole, there is a raised area about a ¼” taller than the opposite hole. This is for the shorter bolt.

CLUTCH CYLINDER AND BRACKET INSTALLATION

Make sure the bleeder valve on the cylinder is pointing upward (high point). See PIC’s for positioning!. You may need to fabricate a clevis. A clutch pedal stop has been recommended to prevent over extending the clutch when pedal is fully depressed.

CLUTCH DISC

Mustang II has 10 spline and is 9 ½” dia.

CLUTCH DISC INTERCHANGE

1974-’79 FORD MUSTANG II, All USA V6 2.8L 171 cid 4 speed manual; 1979 Mercury Capri all USA V6 2.8L171cid; Mercury BobCat; Pinto; here’s a website: www.kyclutch.com recommended by Paul A that does clutch work. Ram Clutch in Columbia, SC also.

CLUTCH RELEASE/THROW-OUT BEARING

With the Mustang II bell housing, flywheel and pressure plate, use the throw out bearing for a Mustang II four speed 1974-1978. Check the fingers on your pressure plate. If the fingers are curved on the ends, use a bearing that has a flat contact surface. If the fingers are flat, use one with a curved contact surface.

Clutches that operate with Hydraulics to activate the clutch disc. RamClutch.com and McLeod racing are a couple suppliers.

CRANK PULLEY/BALANCER

315 H 077 74 & D4ZF-6312-AA (See PIC’s)

CROSS LINK Replacement

My designed cross link PIC’d below is one piece formed in a Hyd Press w/o welding, has threaded ends for tie rods. It comes with 2 new tie rod ends & lock nuts. Adjust to match your stock linkage, approximately 21” center to center of the tie rod ends. Front end alignment is recommended

CROSS LINK Modified

An option less costly but just as effective. Bolts and Spacers (4140) used with your stock Cross link bar to replace stock bolts/pins. Recommend you purchase replacement bushings from one of the Sunbeam Alpine suppliers for your stock crosslink bar/rod with this alternate option pictured below, save about $100.

Distributor and Ignition Parts & Wiring

OEM type Distributors, parts and ignition boxes available as aftermarket parts. Distributor clamp – Mr Gasket 9860 and Lockdown Bolt Kipling Metric 8.8; Mallory and DuraSpark are good for this conversion. Distributor Ignition Control Mustang II Unit 1976-78; Standard Motor Products LX203T. It was recommended that I should salvage/hunt for the electronic ignition from the Mutt II car getting the Brain box & pigtail that connects the unit to the body wire loom in order to connect the wire that corresponds to the “white” wire coming from the “box” to the body. I attempted that on several cars but found most times they were not salvageable. I discovered a new and separate wiring harness that makes things very simple with less mess, a DuraSpark II Ignition Harness Part Number 30812 from Painless Wiring Accessories.

DRIVE SHAFT

Searching in the local Salvage Yard has mostly proven futile when looking for a drive shaft that can be modified for the T5 conversion. My recommendation is have your drive line shop build you a drive shaft suitable to your needs. So why bother? Get the new stuff. Some of the guys that have done this and willing to share are guys like Paul A on the SAOCA Forum who had a custom driveshaft made up using 2.5″ X .065″ tubing. To this was welded a Neapco 2-2-899 flange yoke using a Neapco 10433 U-joint. Machining, welding, balancing and tax came to $189.26. Another great contributor to this project, Jim Nichols, provides this bit of information: The Common C4 Automatic yoke works for the Ford T5. The part# listed is for the Sunbeam stock axle yoke. I always get both needed yokes first and put the front yoke all the way in and pull out 1″. Measure between for your driveline for length. Speedway Motors sells a 2″ tube driveline at a reasonable price in various lengths for the 1310 U joints.

I took a couple of Alpine drive shafts, to a Driveline shop and had them build me a couple for my cars undergoing V6 modifications. The Alpine (rear) and new Front yokes were welded to new tubes then balanced for about $150.00 each. I believe you can get all new parts from a reputable Driveline Shop. Even the Alpine rear yoke as Paul A has pointed out.. A new yoke is cheaper than looking for a used t-bird drive shaft. IMHO.

As an added thought, I recommend you check the yoke for your driveshaft by fitting it in the tail shaft “before” installing the engine and tranny in your Alpine. The first time, I had everything installed before I attempted to hook up the driveshaft. To my surprise the yoke would not slip into the tail shaft but an inch or so. No amount of effort would make it work short of removal of the engine and tranny… UGH! Found the tailshaft bushing was the wrong one!!

ENGINE

2.8 V6 FORD (COLOGNE) Mustang II 1974-1978; Mercury BobCats; Mercury Capris; & Pinto’s; have correct bellhousing; flywheel/clutch pack; & timing cover. I found some ‘79 & ‘80 Mustang’s &Capri’s also have the correct 2.8 V6’s. The ’83-86 Ranger/Bronco II, AeroStar’s 2.8 V6 engine and heads will work. The timing cover will not due to the thermostat configuration, neither will the water pump, its’ snout being too long. The ’79 Mercury Capri is good except the bellhousing is a bit different! If you are going with an Automatic, moot point!

Very similar to the ‘74-78

 

  1. Water inlet connection – Commonly referred to as Thermostat Housing – New stock replacements (Four Season 84861). Need to be Modified! Available in DanR’s Components.
  2. Thermostat – I run mostly the 180 -185’s
  3. Water pump – Ranger/Bronco II will not work for this conversion. Note: Besure to install the water pump before the Harmonic Balancer pulley!
  4. Timing cover – Must be Mustang II or from one of the interchangeable Vehicles. See PIC in later
  5. By-pass hose flange – By pass hose from intake connects here. (Three eared housing). Be extremely careful tightening the bolts (metric) because the ears are aluminum.
  6. Oil seal (front) is best installed using an appropriate tool. When fitting the timing cover utilize the Harmonic Balancer (Hub), as a guide if you do not have a tool. Insert all of the correct metric bolts first before tightening.
  7. Camshaft thrust plate
  8. Camshaft gear – Make sure you get the “all” metal one
  9. Crankshaft gear – Get the metal one!
  10. Flywheel – Mutt II or and interchangeable for the manual transmission. Different, if you elect to go with the Automatic tranny.
  11. Crankshaft pilot bearing – Depends on the transmission you choose. I have the Adapters available.
  12. Oil seal – Rear
  13. Crankshaft – Recommend not to use if over .030 plus
  14. Oil pump drive shaft – Check on some later notes when installing.
  15. Main Bearing block (s)
  16. Oil Pump – Recommend a High volume – Sealed Power High Volume (same as Melling HV) SEP 22441163V (74-78 Mustang II/83-85 Ranger 2.8L)
  17. Oil Pan – Mustang II has front sump – will not work in this conversion. Get Ranger/Bronco II 2wd rear sump pan & pickup. ‘79 Mercury Capri and some early Foxbody Mustang have correct rear sump. Don’t know about Aerostar! AutoZone usually carries them. Same as Pictured above. You will need to modify the Main bearing cap bolt to “add” a stud to the head for securing the oil pump pick up tube brace. I had a stud silver soldered on! Ranger/Bronco II bolts w/stud is too long and not enough threads , so beware!
  18. OIL Filter Adapter (Not shown) – FORD P/N FMS-M-6880-A50 Right angle ¾”-16 threads. Other FORD Dealer a. FMC Fotz61621a Gasket b. SPO E3tz6749a O ring c. SPO E3tz6a636a Copper Washer. These adapters are easily found in salvage yards on the 2.8, 2.9, 3.0 & 4.0 V6’s.
  19. Block plates – The Timing cover to engine block plate is pictured above but not pictured. It is located/PIC’d between Item 7 Cam Thrust plate and the engine block. The Engine to Bellhousing Block Plate is not pictured above. Below are the Automatic on left with the small window/plate and the manual type on the right. Make sure you have them.
  20. The PIC below depicts the Timing Cover to engine plate’s location between the TC and engine block

NOTE: Here is a link to a better understanding on the 60 Degree V6 Engine: http://myplace.frontier.com/~capriclubchicago/Cologne.html

Engine Mounts

Consisting of 2 pieces each side (upper & lower) w/Anchor Rubber Biscuits P/N 2424. PIC below shows the Mounts upside down for a good look at the “stop or catch” that connects to the cross member and locks the engine from going too far forward.

PIC above shows the Engine Mounts rightside up. As pictured they are pointing toward the radiator in mounting position.

ENGINE MOUNT BRACKETS & WHY DanR is offering Engine Mounting Brackets for the 2.8 V6 Mustang II engine installation in an Alpine

The engine mount brackets I bought in an available “kit” at the time, sat off the back edge of the crossmember. A solution given to me was to weld a piece of exhaust pipe for support. Not liking that idea, I designed a bracket with a curved “lip” that catches on the backside edge of crossmember and serves as a “stop” which keeps the engine from moving too far forward. I have fitted several engines mated to the later model Mustang T5; C3/C4 & A4LD transmissions into different Alpines utilizing my Conversion Components & my Straight Back headers without any notable differences. I have at least 1/2 to 1″ clearance between the fan and radiator on my cars. The one with the 1/2″ clearance has an A/C unit installed which requires an additional pulley for the water pump and the harmonic balancer. So they work fine!

For ease of installation, I recommend a “mock-up conversion assembly” consisting of the engine block; engine mounts w/Anchor 2424 biscuits; timing cover; water pump; fan; modified thermostat housing; radiator modified w/upper connection top left; bottom right connection w/ 90 degree elbow underneath the bottom of the radiator pointing directly back toward the opposite side; a set of heads w/ or w/o valves etc.; bellhousing; Transmission (of choice) w/correct tranny mount bracket; and My straight back headers.

EXHAUST SYSTEM

The headers that came with the “kit” I bought when I first started the V6 Conversion were not to my liking, they stuck out the sides right behind the front wheels (15 – 20 degrees) which would be fine for drag racing. Routing of the exhaust pipes was very difficult to get up and under the Alpine for normal driving. The Alpine is already a bit low to the ground, so I wanted headers that would run straight back similar to the Tiger exhaust system and not hang down for the speed bumps and such:) See PIC below of mine…

FAN

Stock Ford P/N D4ZE-8600-AA four blade from a 4 cylinder Mustang II works nicely on two of my cars. One is sporting an A/C unit. No Engine heating problems in Hot Sunny SC. See PIC’s.

Another Fan Option is one offered by fellow V6 ‘er Dennis Michaliga, a Volvo modification.

FRONT END

Rebuilding the front end is not necessary just because you are installing the V6 (approx. weight increase 75 lbs).

FRONT SUSPENSION & Weight of Alpine

I spotted some of SC Transport Police near me and asked if they would weigh my ’67 SV Alpine ST with the 2.8 V6…. Surprise! They were very interested in seeing and weighting it! I pulled into a flat, hard and level surface area and they pulled their scales out for me to drive up on!
Here are the results:
Front left: 620 Front right: 600 Total Front: 1220
Left rear: 550 Right rear: 550 Total Rear: 1100
TOTAL ALPINE WEIGHT 2.8 V6 w/T5: 2320
That is without occupants or any other stuff!

FUEL Block Plate

Oval shaped plate in the PIC.

GAS PEDAL UPPER ROD

Works well with the throttle linkage

Harmonic Balancer Bolts

NOS OEM Ford Crankshaft Pulley Bolt D4ZZ-6A340-A 1974 Mustang. A few left $15.00 each

HEADER BOLTS

Remember the Cologne Engine is Metric. My header bolts are 10mm 1.5 x 20 and 25 in length 12 point heads 12.9. Metric studs/bolts 20 mm in length can be used for the slotted bottom exhaust flange . See my recommended Head Work (modification) for the emission ports.

Header Gaskets

Suggest using with my recommended head modification to emission ports the Hooker P/N 10828 with your headers.

NOTE: Make sure you get gasket that have the division between the “Siamese” exhaust ports as pic’d above!

HEAD WORK

Recommend: New 2.9 intake and exhaust valves, hardened exhaust seats; Port & Polish will enhance breathing and make major difference in the 2.8; Trim gaskets to match ports. Instructions are available for drilling water passage which improves the life of the heads (Cool Heads prevail):) This PIC shows several things that might be of interest to you. First, to the left of my hand & between the exhaust valves you can see two small holes (⅛”) which are pilot holes for the water jacket passage modifications to the Head that will aid in cooling thus saving from cracking; Late model 2.9 Valves are installed; The Headers are my 1st Generation StraightBack’s with ⅜” thick Flanges as recommended by Sven Pruitt, they are not yet “notched”. As you can see notches are in the flange between the headers and the head for demo purposes. All of my headers will come with these notches so you can secure the bottom of the flanges to the heads, thus, eliminating potential exhaust leakages.

Next PIC for the modification of the emission holes & the reason.

This PIC shows the emission holes plugged up! Next step is to drill and tap the Emission/PCV/Air holes in your heads using 10 mm 1.5 about ¾” deep using your new Straight Back headers or the Hooker 10828 as a template. Now you can finally tighten the top two bolts and not fear exhaust leaks:)

PIC’d above are the plugs used to “fill” the emission holes available in most all machine shops and PIC’d below the “plugs” before being cut off smoothly. Followed by drilling and tap work (10mm 1.5 thread).

HEADERS, STRAIGHT BACK

Designed for better performance, zero ground clearance problems and ease of routing the exhaust system.

Similar to the Tiger system & not sticking out the sides nor hanging down below the frame

WILL THEY FIT? I’ve been asked if my Straight-back Headers for the 2.8 V6 will fit on an Alpine with the jose kit? They have been fitted to several Alpine V6 conversions without difficulty. Chances are if you welded a piece of exhaust on the rear of the crossmember you may need to remove it before welding my bottom mount bracket piece in place. As for one of my Alpines, the GT BW35 that had the jose “welded nut”Kit washer on the back of the crossmember, I simply slipped the “Bottom Piece” of my mount bracket with the curved “catch” over the “kit washer” and welded it in place without any changes to the Headers, the Steering or Transmission.

HOSE, Water, Heater By pass, etc

1974-1978 Ford Mustang II Bypass Hose – Dayco 70773 or Gates or ? In the below PIC my Machine Guy welded in a fitting that adopted to the Bypass hose. Just one means of making it work.

Pic’d below is a Stock Metric Nipple 22MM 1.5 threads that screws into the Intake manifold for the bypass hose. They are most likely corroded as this one and needing replacement. Replacements are difficult if not near impossible. Several solutions can be found. See the hose picture above, just below the Temp sending unit and the ones below for some ideas.

OIL Filter Adapters

M-6880-A50 Adapter, Oil Filter, Right Angle, Aluminum, Natural, 3/4-16 in. Thread, Ford, Lincoln, Mercury,

Comes on all Ford V6s, from 2.8, 2.9, 3.0 and 4.0 & many others. You should be able to find one easily. (FORD oil filter adapter Part number FA141). I usually find them in the Salvage Yards for $15-30 bucks.

OIL FILTER

Recommend a short one for adequate clearance of the headers like the WIX 51348.

OIL PAN

Oil Pickup Bolt(s) One a Kipping 8.8 is 1/4×3/4”x 24 TPI. RockAuto.com and AutoZone sells correct oil pans (Rear Sump)‘83-’86 Ranger/Bronco II for $64, Mutt II’s will not work. Be sure to use the special rubber gasket with this oil pan and a rear oil pump pick up and the special main cap bolt that has a screw sticking up on the head for bolting the oil pump pickup tube to keep it from fatiguing from vibration and breaking off.

OIL DIPSTICK

There is a small plug covering the rear dipstick hole in the Mutt II engine block. While the pan is off, knock it out and install it in the front hole where the dipstick presently resides. Move the dipstick from the front driver side, to the rear driver’s side hole. A Ranger/Bronco II dipstick reads correctly (Remember the rear sump oil pan?).

OIL PRESSURE CONNECTIONS

Normally you will find the best connection just below where the manual fuel pump was connected. (Now the Fuel Pump Block Plate) See PIC. Some Conversions have utilized an electric sending unit. I used a 90 degree elbow and a copper line. Very tight, but doable. See PIC.

OIL PRESSURE SWITCH

Standard P/N PS-64 recommend for emergency shut off.

OIL Pump Driveshaft

Melling IS-87 – Melling Heavy-Duty Intermediate Driveshafts Summit Racing has them for $8.73. AutoZone also carries them for 9-10 bucks.

PARTs & Numbers for 2.8 V6

May be of help

  • 8546-A FAN BLADE SPACER MOUNT V-6
  • 8600-A 2800 V-6 FAN BLADE 74-78
  • 6B070-A PLATE ASSY 2.8 V6(TIMING COVER & BLOCK)
  • 6A340-A V-6 CAMSHAFT PULLEY BOLT
  • 6023-A V-6 TIMING POINTER.

PILOT BEARING

I think best to get an adapter to fit your pilot shaft spud if needed.:) Here is some good reading material for the T5’s.
http://www.allfordmustangs.com/Detailed/349.shtml

PILOT BEARING RETAINER/Housing

Needs to be shortened to the length of the 5.0 T5 (4”). And the diameter of the collar also needs to be milled/turned down to fit snugly in the opening of the Mutt II bellhousing. The Bellhousing ID is 4.850″ so to mate with a slip snug fit, the Input Bearing Retainer Collar diameter should be turned to 4.846″ +/- 0.001″. See PIC

PRESSURE PLATE

Mustang II part number is D4ZA 7563

PULLEY

Water pump & pulley part# is D5ZE-8509-AA is the best. Don’t go with the one ending in CA because that is a 302 pulley.

RADIATOR MODIFICATION

Highly recommend you Modify your stock radiator with a heavy duty Copper three row/core & 17 fins per inch, & have the top left connection angled about 10 degrees toward the water neck and slightly 3 to 6 degrees upward. With the bottom connection plugged off & a 90 degree elbow added underneath the bottom of the tank, pointing directly back towards the opposite side. Pic’d below is one of my Radiators modified with top left and bottom right connections. The Radiator Fan shroud I fabricated also helps route the flow of air. I am trying to get some of these made too!. This is the engine side.

This is the engine side.
The above PIC depicts a view from the front of the Alpine.

The 90 degree elbow underneath the bottom of the tank makes for a smooth, easy, no hassle connection to the Modified Thermostat Housing ON THE OPPOSITE SIDE OF THE RADIATOR.. Trim the Gates hose 22080 to fit. Of interest also is the drain plug… Move it to THE RIGHT SIDE closest to the outside of the tank facing the engine (Pictured ON LEFT here) so as not to interfere with the hose.

Also in the above PIC is the Modified Thermostat housing with the Heater Option (drilled and tapped with a NPT plug. Cooling Depot Part number 84719 is a nipple that fits for the ⅝” heater hose.

There are ideas for using the Ranger timing cover by either moving the radiator forward and down, or shorten the water pump shaft to where the overall length is the same as the Mustang II pump. A modification of the Ranger timing cover hasn’t been found that I know of. The bolt patterns of the two Timing covers match except for the thermostat housings. Still would like to see this timing cover/water pump modified for this conversion. Anyone game?

Radiator Hoses I found to work, cut to fit are: GAT 22356 Top & GATES 22080 Bottom. Note here also the other option for the top hose……Gates 21341 if the unmodified water neck is utilized.

REAR END

Depending on how much power you intend on getting from your 2.8 V6, you could keep the stock rear end, thus saving you money and work. The stock rear end is pretty strong, check the ring gear bolts and swap out the soft stock woodruff keys. The SV’s are the stronger! I just changed out the wires to the four bolt hubs.

Rear Axle Options

One option, a Dana 44 from a 1970 Jeep DJ-5. Yes DJ as in 2wd Postal Jeep. It’s 49″ flange to flange and a 3.73 with Trac-Lok. kinda makes you think about using a 8.8 out of a mustang. My SV Rear axles are satisfactory for me.

SLAVE CYLINDER MOUNT BRACKET

Comparison between two brackets, Mine on the right sits further back toward the rear of the engine away from the heat generated by the Headers, hopefully prolonging the life of the Slave Cylinder

The next two PIC’s are showing the different slave cylinders in use in my Bracket. Note that if you elect to utilize an internal clutch Hyd release bearing the Slave Bracket is not need. Please take note the “bleeder” should be on the top side:)

SPEEDOMETER

In order to run a factory Rootes speedometer with the different transmission (T5-five speed conversion), the cable must be changed on the transmission end to fit the five speed. The upper ferrule stays the same and works just fine. If you are using a Tiger speedo, a factory issue or aftermarket Mustang cable of 64 to 66 vintage has the correct connections on both ends and is just the right length. Cactusmasher discovered this recently when He changed His speedometer from Alpine to Tiger.
I had good results with Texas Industrial Electrical tie@texasindustrialelectric.com Sent one of my Alpine Speedometers and a matching Alpine cable to them (Steve) to have the transmission gear end fitted to a late model Mustang T5.

SHIFTER BOOT

One choice is the MGB:OEM SHIFTER BOOT & RETAINER w/screws 72-80 MGB MGBGT

TACHOMETER

Your 4 cyl needs calibration to the V6. TomH on SAOCA is the Gent to see.

TIMING COVER

Ford part Number 74 TM 6059 AA. Obtain from a Mustang II ’74-78, 2.8 V6 & other interchangeables such as Pinto, Mercury Capri & Bobcats.

THERMOSTAT HOUSING

Modified and has ¼ NPT plug for heater option

To add the heater connection obtain a Cooling Depot P/N 84719 Nipple ¼ Male NPT w/ ⅝” hose end.

Transmission Brackets

Available for T5; C3/C4 and A4LD transmission for Sunbeam Alpine mated to the 2.8 V6. Whether you have a stock 4 spd or the Borg Warner BW 35 Alpine, I have a Bracket for you.
Comments: Hi Ken, I have seen pictures of Dan´s crossmember and it will work beautifully. I suggest getting one. It will simplify your job a lot. Jose

PIC’d below is my 1st Generation Tranny bracket for a T5 in my Alpine that came from Rootes with an Automatic Borg Warner BW35. The three bolt pattern is for an automatic Alpine. Later BW35 bracket are laser cut and formed as one piece similar to the 4 speed Alpine style.

First generation.
Above is a Bracket for an Automatic C3/4 transmission in a standard tranny Alpine (see the 4 bolt pattern).
T5 to 4spd Manual Alpine has 4 bolt pattern

All of my Transmission brackets for BW35 Alpines will be three bolt pattern. Likewise, all Brackets for the Standard/Manual 4 speed Alpines bolt pattern will have four.

T5 TRANSMISSION

The chart below identifies various T5 applications and their specifications.  The choice of your transmission may be a personal preference, availability and cost. Comments following may provide you with some fodder……

B/W Id Source Application Torq Max (lb/ft) Gear Ratios Input Shaft length
1352- Year Model Engine 1st 2nd 3rd 4th 5th R
220 Factory 94 Mustang 3.8 265 3.35 1.93 1.29 1 0.73 3.15 7.85
236 Factory 94 1/2 Mustang 3.8 265 3.35 1.93 1.29 1 0.73 3.15 7.85
238 Factory 94-97 Mustang 3.8 265 3.35 1.93 1.29 1 0.73 3.15 7.85
126 Factory 85 Mustang 5 265 3.35 1.93 1.29 1 0.68 3.15 7.18
141 Factory 86 Mustang 5 265 3.35 1.93 1.29 1 0.68 3.15 7.18
165 Factory 86 Mustang 5 265 3.35 1.93 1.29 1 0.68 3.15 7.18
219 Factory 94 Mustang 5 300 3.35 1.99 1.33 1 0.68 3.15 7.85
169 Factory 86.5-89 Mustang 5 265 3.35 1.93 1.29 1 0.68 3.15 7.18
199 Factory 90-91 Mustang 5 300 3.35 1.99 1.33 1 0.68 3.15 7.18
208 Factory 92-93 Mustang 5 300 3.35 1.99 1.33 1 0.68 3.15 7.18
246 Factory 94-95 Mustang 5 300 3.35 1.99 1.33 1 0.68 3.15 7.85
218 Factory 93 Mustang Cobra 310 3.35 1.99 1.33 1 0.68 3.15 7.18
242 Factory 94-95 Mustang Cobra 5.0 310 3.35 1.99 1.33 1 0.68 3.15 7.85
115 Motorsport 79-83 Mustang 5 305 2.95 1.94 1.34 1 0.63 2.76 7.18
200 Motorsport 79-93 Mustang 5 305 2.95 1.94 1.34 1 0.63 2.76 7.18
227 Motorsport 79-93 Mustang 5 325 2.95 1.94 1.34 1 0.63 2.76 7.18
249 Motorsport 79-93 Mustang 5 33 0 2.95 1.94 1.34 1 0.63 2.76 7.18
204 Service 85-89 Mustang 5 300 3.35 1.99 1.33 1 0.68 3.15 7.18

Note that the Input Shaft Length on some of the V8 models are about 5/8″ shorter than others.  A T5 with the 7.18″ shaft requires a Pilot Bearing Adapter to extend the pilot bearing and compensate for the shorter input shaft.  AS NOTED BELOW: The shorter shaft does not require modification, however you will need to use a Type 2 pilot bearing adapter.

COMMENTS: Hi, Dan: The input shafts should be the same length, my trans is a 238, out of a 1996 Mustang with a 3.8 in front of it. I like the gearing on that trans. I made a pilot bearing adapter that pressed into the flywheel, because the input shaft on these transmissions are just a bit short, and will not go all the way into the existing pilot bearing if installed in the way the factory calls for…the original 4 speed had a longer shaft, by about .750″, than the T5. My adapter will press into the existing flywheel, and use the factory pilot bearing.
PS, I did run my motor for 2 years without the pilot bearing adapter…I installed just as the factory recommends…so it will work, I just don’t think it is ideal. Kelly Mathis

TRANSMISSION SHIFTER

Comment: The factory shifter does not have positive stops and the shift forks can get bent. Also the aftermarket shifters have a spring to assist 2nd to 3rd. I have had good luck with the $40 Ebay Mustang T5 shifter. Not too fond of the boy racer colored shift lever. Try to find the silver or black one. http://www.ebay.com/itm/RACING-SHORT…odel%3AMustang – Jim Nichols

Transmission Rubber Mount

T5 1975-1978 Mutt II Transmission Mount – Westar EM-2566 … Check the height compatibility with the T5 Transmission Bracket ? Might need 2565 or maybe 2784 which is 2 ¾” tall. Alignment in the tunnel will be very close so check for adequate clearance.

Transmission Data on An AUTO for the V6 Alpine

V6 Tranny Data for Auto A4LD 4 speed w/OD identified by “T” in transmission code. Overall length 28.687”. In being since ’86. Newest Version has 5th gear (Computer controlled) Upgrades available in an off road package for manual control. Google: Will an A4LD bolt to a 2.8 (Advance Adapters). Readily adapts to the V6 60 degree engines.

Transmission Tunnel Modification

Recommend you read the Article By Jim Ellis at the SAOCA site.

http://www.sunbeamalpine.org/index.php?categoryid=90&p2_articleid=25

PIC’s below are taken from the Article.

SPECIAL NOTE: If you choose to utilize the internal Hyd release bearing, you can remove the clutch release rod/bell crank from the Mutt II Bellhousing and forgo extensive tunnel modification.

Step #1 – Mark the floor to cut.
Step #11 – Mark the tunnel for the shifter cut out.
Step#11b – Make the cut out.
Step#11c – Rebuild the sheet metal to use factory cover.

VALVE COVERS

Cologne 2.8 V6 rocker covers: These custom covers are unique by Redmond Metalcasting (jrcast.org).

WATER PUMP

Here are a couple used ‘74-’78 Mustang II 2.8 V6 water pumps, note in the lower left of the picture you will see a small square hole, it is a good identifier between the Mustang II and the later 2.8 engines in the Ranger and Bronco II’s.

If you have comments, questions, & suggestions, please contact Dan Richardson

E-mail: tiger2dan@gmail.com or call 864-554-0814

Thanks for viewing,

DanR

P.S. You may search for additional info at:

  1. TigerDan’s Link: http://danr.mhartman.net/
  2. SAOCA http://forum.sunbeamalpine.org/index.php
  3. The TE/AE Tigers East/Alpines East  A nice Article on the “First V6 Conversion” http://teae.org/capri-v-6sunbeam-alpine/
  4. The Sunbeam Experience http://www.sunbeamclub.com/