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Too bad I missed this post from earlier. I was going to tell you if you need any "new" Ford parts, one of my favorite places to go is https://www.partsgalaxy.com I can't count how many times they have saved my behind when I needed a part.
Sorry to hear of your clutch probs. You may have an easier fix by changing the slave or master diameter. Larger on the master and/or smaller on the slave so less pedal yields more throw.
The annular slave on the Tremec is from a late model Mustang with V6, as I said, but a search of the web yielded no info on a factory stock setup. I did find an outfit that specializes on annular slaves, Dorman Clutch. Summit sells some of their stuff. They list a slave for a 2006 V6 Mustang, which would have the T5 - a late model of it; can't guarantee the bolt pattern is the same, but I would be surprised if they changed it. Or perhaps match the slave to the vehicle type that the tranny came out of.
I don't know if the stock one is a push or pull - I would assume a push but I have seen advertisements of similar looking units as both push and pull. I can tell you it mounts directly to the front snout ot the T5, just like this Dorman, with the integral throwout pointing forward and the hydrolic input toward the tranny.
I may have the same issue when I hook this up to the TVR master.... You may as well - and have to change the master even with this annular slave.
Do you have an update on your 4.0 conversion? I just bought a non running 280i that you have my intrest peaked about converting to a 4.0 (though I'd love to do a newer stang 4.0 SOHC and 5 speed) as they seem cheap as dirt with sub 20k on the odo. Just saw one with 200 miles for $500 complete with engine, wiring harness, computer and an auto tranny (hence why I waited.
Thought I,d pass this along, camaro LS1 uses the similar slave setup& while I was working at a turbo shop(5 yrs) we did alot of these& GTO's& with alot of competition clutch setups they included a aluminum spacer that went behind the slave assembly(held in by the 2 mounting bolts) inorder for the clutch to disengage completely.It was 3/16-1/4 inch thick. Without it you had to pump the clutch to make it work fully.Also on these you had to follow OEM bleeding procedures. hope this helps cheers Genos2
Start with a 2005-2007 (or later) 4.0 V-6 & Tremac 5 speed
<span style="text-decoration: underline">Flywheel </span>6 bolt flywheel (Mustang or Ranger???)
<span style="text-decoration: underline">Starter</span> from a manual Mustang
<span style="text-decoration: underline">Clutch slave </span>- did the original Mustan one work?
<span style="text-decoration: underline">Drive shaft</span> Modification to the front end of the drive shaft
Did you guys ever finish this, take pictures, have a parts list??? Any help would be appreciated. Grady