Last Update: 02/11/2018
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. 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 1983-85 Ranger/Bronco II’s and some Aerostars. The early 2.8’s are common with the 2.9, 3.0 & 4.0 V6’s except for one major characteristic, the Siamese exhaust ports. 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.
The Cologne engine seems to be a natural fit for the Alpine. Removal of the original engine mounts is the only necessity, so you will not be butchering your Alpine. Installation is made easy with the use of my two piece engine mounts consisting of, a top bracket that is bolted to the engine & the Anchor 2424 rubber biscuits connecting to a bottom piece that serves as a “Stop or catch” on the crossmember and keeps the engine from being placed too far forward, 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
Transmission selection “may” determine your need for an adapter. If you elect to go “Automatic” the adapter is not applicable. See PILOT Bearing.
Various choices some like the 9” Spectre P/N 4770 Here is a nice Breather on SD Pace’s 2.8 V6.
Notice He is running an A/C unit too. Top hose to radiator modified as I recommended for a better fit down below with the modified Thermostat housing. 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.
I like the Delco single wire. It is available in about any parts store if you should need one while away from home. Another one popular is the Hitachi 14231 (Advance Auto) from a 1973 Datsun Truck.
ALTERNATOR BRACKET W/Adj Arm
The two piece bracket mounting holes are slotted allowing for precise alignment of your alternator. Below PIC shows Bracket in place w/bolts.
Solenoid to starter Standard A32-1L 1 gauge 32” long. Runs from starter solenoid on firewall to the starter.
How to identify 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 removed to provide clearance for a slave cylinder to function.
What choice of cam to use has/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 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 go to it!
You have several options. Run a stock setup (2bbl) or a 4 bbl OFY intake with a Holley 390 4BBL Carb (pictured below) which is a very good performer for the 2.8 V6. In 2nd PIC the stock water neck points to the right side of the Alpine. 3rd PIC shows both angles. As PIC’d below the water neck has been modified to turn toward the left side of the radiator. I recommend modification to point to the left for a simpler connection and routing of the Hoses. (See Radiator modifications for directions). Lots of good selections on the Custom Valve Covers too!
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 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.
For clutches that operate with Hydraulics to activate the clutch disc. RamClutch.com is one such available. McLeod 1319 assy ? http://www.mcleod.com/application_guide/hydtob ?
CROSS LINK and Tie Rod Ends/ Bolts and Spacers
My designed cross link PIC’d below is one piece formed and threaded for tie rod ends. 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.
An Alternate to the Cross link with tie rod ends is my designed Bolts and Spacers used with your stock Cross link bar. Recommend you purchase replacement for your stock crosslink. With this alternate option for a crosslink you can save $100.00.
OEM type Distributors, parts and ignition boxes available as aftermarket parts. Distributor clamp – Mr Gasket 9860 and Lockdown Bolt Kippling Metric 8.8
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.
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. MY Drive shaft modifications used a CAM784 Part Number for the yoke.
I Took a couple of Alpine drive shafts, to a Driveline shop and had them build me a couple of drive shafts for my cars undergoing 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.
2.8 V6 FORD (COLOGNE) Mustang II 1974-1978; Mercury BobCats; Mercury Capris; & Pinto’s; have correct bellhousing; flywheel/clutch pack; & timing cover. The ’83-85 Ranger/Bronco II timing cover is configured differently and the water pump will not clear the Radiator on the Alpine. The ’79 Mercury Capri is good except the bell housing is a bit different! If you are going with an Automatic, moot point!
- Water inlet connection – Commonly referred to as Thermostat Housing – New stock replacements (Four Season 84861). Need to be Modified! Available in DanR’s Components.
- Thermostat – I run mostly the 180 -185’s
- Water pump – Ranger/Bronco II will not work for this conversion. Note: Besure to install the water pump before the Harmonic Balancer pulley!
- Timing cover – Must be Mustang II or from one of the interchangeable Vehicles. See PIC in later
- By-pass hose flange – By pass hose from intake connects here. (Three eared housing). Be extremely careful tightening the bolts in the ears because they are aluminum.
- 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.
- Camshaft thrust plate –
- Camshaft gear – Make sure you get the “all” metal one
- Crankshaft gear – Get the metal one!
- Flywheel – Mutt II or and interchangeable for the manual transmission. Different, if you elect to go with the Automatic tranny.
- Crankshaft pilot bearing – Depends on the transmission you choose. I have the Adapters available.
- Oil seal – Rear
- Crankshaft – Recommend not to use if over .030 plus
- Oil pump drive shaft – Check on some later notes when installing.
- Main Bearing block (s) –
- 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)
- 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!
- 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.
- Block plates – The Timing cover to engine is pictured above (but not numbered). 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.
- The PIC below depicts the Timing Cover to engine plate’s location between the TC and engine block
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.
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.
Rebuilding the front end is not necessary just because you are installing the V6 (approx. weight increase 75 lbs).
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
Remember the Cologne Engine is Metric. 10mm 1.5 x 25 12 point heads 12. come with my headers. Included also are metric studs/bolts 20 mm in length for the slotted bottom exhaust flange. See my recommended Head Work (modification) for the emission ports.
Hedman #500-27110 Ford 2800cc 2.8L 2/pkg & Hooker P/N 10828
NOTE: Make sure you get gasket that have the division between the “Siamese” exhaust ports as pic’d above!
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 Straight Back’s with ⅜” thick Flanges as recommended by Sven Pruitt they are not yet “notched”. Notches are in the flange on the head. 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.
This PIC shows the emission holes plugged/welded up! Next step is to drill and tap the Emission/PCV/Air holes in your heads using 10 mm 1.5 about ⅝ to ¾” deep using your new Straight Back headers as a template. Now you can finally tighten the top two bolts and not fear exhaust leaks 🙂
HEADERS, STRAIGHT BACK
Designed for better performance, zero ground clearance problems and ease of routing the exhaust system.
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 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; Steering or Transmission.
HOSE, Water, Heater By pass, etc
1974-1978 Ford Mustang II Bypass Hose – Dayco 70773
Pic’d below is a Metric Nipple 22MM 1.5 threads that screws into the Intake manifold for the by-pass hose. See the hose above, just below the Temp sending unit.
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.
Recommend a short one for adequate clearance of the headers like the WIX 51348.
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) for $64. 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.
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 SWITCH : Standard P/N PS-64
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.
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.
PILOT BEARING RETAINER/Housing
Needs to be shortened to 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″.
Mustang II part number is D4ZA 7563
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.
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 15 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!
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?
NOTE: Radiator Hoses I found to work for the 2.8 V6 are: GATES 22356 Top & GATES 22080 Bottom.
Comments: Cut 2” from one end (close) towards the Radiator and about 4 to 4 ¼” from the end near the Outlet on the intake (Ofy). See PIC’s of the Radiator modifications recommended.
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
This little beauty is 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.
SLAVE CYLINDER MOUNT BRACKET
Comparison between two brackets, Mine on the right sits farther 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.
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 firstname.lastname@example.org phone # 210-654-7075. I sent one of my Alpine Speedometers and a matching cable to them (Steve) to have fitted to a late model Mustang T5.
Ford part Number 74 TM 6059 AA. Obtain from a Mustang II ’74-78, 2.8 V6 & other interchangeables.
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. I have since improved upon my Brackets by utilizing a laser cut then molding & forming them in one piece by a hydraulic press. (See the three bolt pattern for an automatic Alpine).
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.
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
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
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
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 a 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.
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.
Cologne 2.8 V6 rocker covers: These custom covers are unique to Redmond Metalcasting (jrcast.org).
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: email@example.com or call 864-554-0814
Thanks for viewing,
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