Jezza's Ford 6R80 Transmission Swap

Crank sensor for the flywheel is mocked up. I made a template that locks into a dowel pin and a bellhousing bolt. The template aligns the sensor to the proper location on the 6R80 transmission bellhousing. Then it's a simple drill and tap routine. Screw the sensor in until it bottoms out and back out a half turn. It should work as good if not better than the oem system.

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Spacer is cut. I have a few things I need to address. The dowel pin holes on the 4.0 side are tight. Like pull on with the bolts tight. They did seat, but it's going to be a pain getting it apart. Also the countersinks aren't quite deep enough, but that's an easy fix.

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Jezza said:
Spacer is cut. I have a few things I need to address. The dowel pin holes on the 4.0 side are tight. Like pull on with the bolts tight. They did seat, but it's going to be a pain getting it apart. Also the countersinks aren't quite deep enough, but that's an easy fix.

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Wow your progress is phenomenal! Well done sir
 
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Tested the spacer, corrected the countersinks, and fixed the dowel pin fitment. Then I started cutting the flexplate spacer. I need to adjust the fitment for the torque converter hub and crank bore, and drill the holes for the flexplate to bolt up. Chamfer, deburr and balance still before assembly.


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That’s incredible. Can we see one with torque converter bolted up?
 
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I was a bit confused when you started cutting up that flywheel, but I completely forgot that you're putting this setup in an 05. Makes perfect sense now!
 
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