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TREMEC TKX Five Speed Transmission Install

By Barry Kluczyk   –   Images by the Author

After years of overdrive-transmission swaps, we don’t need to waste words on extolling their highway-cruising virtues, but when it comes to adapting the popular TREMEC five- and six-speed transmissions, there have been compromises.

001 1969 Chevy Chevelle SS 396 undergoing engine work and transmission installation
The project car is a ’69 Chevelle undergoing a comprehensive restomod makeover, including an EFI system on its big-block engine, brake and suspension upgrades, and more. An overdrive transmission will help make it a more comfortable and fuel-efficient highway hauler by knocking down the top-gear cruising rpm.

For five speeds, the TKO500 and TKO600 work well with old-school small-blocks but aren’t well-suited for the higher-revving capabilities of LS and LT engines. When it comes to six-speeds, there are basically two choices: the production-based T-56 and aftermarket-intended and T-56–based Magnum. Used T-56 units are getting scarce and for most vintage Chevys the shifter replacement typically requires modifying the trans tunnel. The relatively bulky Magnum also requires modifying the tunnel—and usually it’s to create room for the Magnum’s wide case and not just the shifter.

002 Tremec 5 speed manual transmission on display for a Chevelle swap
The TKX transmission is designed for retrofit installations in older cars with slimmer transmission tunnels. It is a little less than 31 inches in length and only 10.5 inches wide. It also offers a 600 lb-ft of torque capacity and, depending on the model, an overdrive ratio as high as 0.68:1. TREMEC ships their transmissions without oil, so it has to be filled at the time of installation.

To address those fitment challenges, TREMEC introduced the TKX about four years ago. It’s a five-speed specifically designed for retrofit applications. It has a slimmer profile that slides into most vintage cars’ trans tunnel with little or no clearance issues. There are even specific versions for GM and Ford applications, with unique case patterns and inputs, along with integrated transmission mounts.

Read More: Installing Holley’s Lo-Ram Manifold on a Fourth-Gen F-Body

003 Tremec label and sensor detail during transmission swap for Chevelle
Specific GM and Ford versions of the TKX include brand-unique inputs, including a GM-compatible vehicle speed sensor for an electronically controlled speedometer. There’s also an input for a mechanical speedo drive, but it uses a Ford-type drive. An adapter is required when using a GM cable.

Even better, it was also developed to complement the higher-rpm capability of modern LS and LT engines, handling rev ranges of up to 7,500 rpm and matching that with a 600 lb-ft of torque capacity. We recently followed the installation of TKX in a ’69 Chevelle at the Detroit-area shop Stellar Rod and Custom, but rather than an LS or LT the vintage A-body was powered by an EFI-fed big-block. The engine was also backed by an automatic transmission, adding another wrinkle to the project, as changes were required, including swapping the flexplate for a flywheel and adding a new pedal assembly that included a clutch pedal. Ironically, the shop had to cut into the transmission tunnel, because there wasn’t a shifter hole in it.

004 Pedal assembly and wiring setup in 1969 Chevelle for transmission conversion
Because the car had an automatic transmission, the original brake pedal was removed and replaced with a new clutch/brake pedal assembly. Additionally, a slave cylinder for the hydraulically operated clutch was also installed on the engine compartment side of the firewall. The push rod for it can be seen here, passing through the new mounting plate on the firewall.

“It was all pretty straightforward because apart from the shifter hole there were no other tunnel modifications required with the TKX,” Mike McKeehan, Stellar’s chief wrench-turner, says. “It slips into place very easily.”

005 Clutch master cylinder installed in 1969 Chevelle during transmission swap
Underhood, the slave cylinder is partnered with a fluid reservoir. This hydraulic system reduces pedal effort and offers generally smoother gear engagement than a mechanical clutch, with no need for follow-up adjustments.

An installation kit with the requisite bellhousing, pilot bearing, throwout bearing, slave cylinder, and so on, is also required. They’re offered from a number of companies, like Speedway Motors, but the one sourced for this project came from Silver Sport Transmission (SST), which included those swap parts in addition to the transmission and flywheel.

Read More: Inspecting an Engine of Questionable Origin

006 Installing a red twin disc clutch system in a 1969 Chevrolet Chevelle SS
The installation kit included a flywheel to replace the previous automatic transmission flexplate. A separately sourced McLeod RST twin-disc clutch that aligns with the 26-spline input shaft that’s common among TREMEC transmissions was bolted to it.

SST also supplied the pedal assembly, along with a reproduction transmission hump for the interior that matched what came on original manual-transmission models. And while a shifter was included with the transmission, the project car’s owner opted for a different aftermarket versions.

“All the swap parts fit as intended,” McKeehan says. “Thankfully, there were no surprises or hang-ups with the installation.”

007 Fitting the new bellhousing onto the flywheel in 1969 Chevrolet Chevelle SS
Next, the aluminum bellhousing is slipped into place and bolted to the engine, after making sure no wires or hoses had drooped in the way.

It’s not an exaggeration to say the slimmer profile of the TKX case makes installation easier, but the conversion from an automatic to a manual transmission required a bit of follow-up trimming after the initial measurements were made for the shifter hole. It was really nothing in the grand scheme of the entire swap. A lift made the project infinitely easier and while we know many a transmission has been swapped with just floor jacks, the details involved in converting from an automatic to a manual makes a lift all but a necessity.

008 Dial indicator used to center the bellhousing for Tremec transmission on Chevelle
An important step to ensure the proper centerline relationship between the crankshaft and the transmission’s input shaft is measuring the bellhousing’s runout with a dial indicator. Even a slight misalignment can result in excessive side loads, poor clutch-to-flywheel alignment, and premature wear. Shift quality also suffers and driveline vibrations are likely.

We’ve outlined the basics of the project with this story, but it’s also worth noting the installation was performed on a car that was also undergoing additional significant upgrades, from the wiring system to the brakes and more. That meant a road test of the Chevelle with the TKX wasn’t immediately available.

Read More: Tying up Loose Ends on the 383 Small-Block Install in our 1969 Nova

009 Underbody of 1969 Chevelle SS showing exhaust system before transmission installation
With the flywheel, clutch, and bellhousing installed, attention turns to prepping previously automatic-equipped body for the manual transmission. There’s no hole in the floor for a shifter.

Nevertheless, the project was surprisingly straightforward, and the new five-speed transmission slid into the A-body like an old shoe. And with inclusive swap kits going for typically less than $4,500, including the transmission itself, it’s a smart restomod upgrade to put your vintage Chevy in overdrive.

ACP

010 Tremec transmission being installed underneath a 1969 Chevrolet Chevelle SS
The TKX is slowly and carefully inched up into the tunnel to gauge the general position for the hole that needs to be created in the floor.
011 Adjusting the shifter mechanism during Tremec transmission installation in Chevelle
The shifter that came installed on the transmission required removal to raise the transmission to the proper location for its test-fit.
012 Technician prepping the transmission tunnel for modification in a Chevelle
After the general location for the shifter hole was determined and a pilot hole drilled for it, the car was lowered on the lift and a factory-style reproduction manual transmission “hump” was placed on the floor and the opening for the shifter was traced onto the tunnel.
013 Cutting the transmission tunnel to fit the new Tremec shifter in the 1969 Chevelle
Next, the hole was cut into the floor.
014 Close up of Tremec transmission installed in the 1969 Chevelle SS
Although very close, the hole wasn’t quite large enough for the shifter platform.
015 Finalizing the transmission tunnel modification with pneumatic tools in the Chevelle
A little more trimming at the rear of the hole did the trick.
016 Aligning the bellhousing with the Tremec transmission on a 1969 Chevelle
Moving to the final installation, the hydraulic throwout bearing (also known as release bearing) was slipped into the bellhousing, after its clearance tolerance was checked first on the transmission’s input shaft.
017 Applying lubricant to input shaft before final assembly of Tremec transmission
A bit of grease on the non-splined areas of the input shaft is OK, but greasing the splines risks them flinging the material onto the clutch disc, which is not good. The pilot bearing can also be greased lightly, but the pilot bushing should not be greased.
018 Lifting and fitting Tremec transmission under the Chevelle for bolting
In goes the transmission for the final time. The throwout bearing aligns with a pin on the transmission to ensure everything is oriented correctly. The connections for the electronic speedometer, backup lights, and so on, will be made later in the car’s overall project.
019 Tightening the transmission mount after installing Tremec transmission in 1969 Chevelle
The transmission’s tailhousing incorporates a pad for GM trans mounts and a new one was bolted to it.
020 Mounting the Tremec transmission crossmember under the 1969 Chevrolet Chevelle
Using a standard GM mount means the original transmission crossmember can be reused. That’s one less part to purchase or fabricate.
021 Technician finalizing transmission alignment under the Chevelle after installation
Although the crossmember can be reused, the length of the new transmission repositions it on the frame. In this case, it moved rearward.
022 Drilling holes in the chassis to secure the transmission crossmember on the Chevelle
New holes must be drilled into the frame channel to accommodate the mounting hardware for the crossmember’s revised position.
023 Tightening the crossmember bolts during Tremec transmission installation in the Chevelle
Finally, the crossmember is snugged into place at the transmission and the framerail positions.
024 Setting up the shifter inside the Chevelle with soundproofing in place
Back inside the car, the shifter is reinstalled.
025 Installing a custom Hurst shifter in the transmission tunnel of the Chevelle
After that, the shift handles and the new manual-transmission hump are installed. With a bead of sealant around the bottom flange, the hump will be simply screwed to the floor with a few sheetmetal screws.
026 Highlighting hydraulic clutch line routing for the Tremec transmission
Wrapping up the installation is the connection of the throwout bearing’s hydraulic line (arrow) to the slave cylinder. The hose for the fluid reservoir is seen in front of it. The system will need to be bled before the car is driven, but that will come later in this project, with the brake system also addressed.
027 Inserting the driveshaft into the Tremec transmission in a 1969 Chevrolet Chevelle
The car will also need a shorter driveshaft, with a slip yoke to match the TKX’s 31-spline output shaft. There’s more work to do on this restomod project car, but the transmission is done.

SOURCES
McLeod Racing
(714) 630-2764
mcleodracing.com

Silversport Transmissions
(865) 609-8187
shiftsst.com

Speedway Motors
(855) 313-9173
Speedwaymotors.com/allchevyperformance

Stellar Rod and Custom
(248) 849-0224
stellarrodandcustom.com

Click on this issue’s cover to see the enhanced digital version of TREMEC TKX Five Speed Transmission Install.

acp september 20240

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