2003 Terminator Cobra: Fixing Factory Defects & Upgrading Transmission Before Catastrophe!

Initial Factory Defect Fixes

• 💡 The 2003 Terminator Cobra Mustang was initially overheating due to a swapped radiator and intercooler cap, causing coolant to boil over. This was a free fix.
• ⚙️ After discovering head studs were already installed, the engine was running well, but a clutch smell indicated an issue needing attention.

Teaching Stick Shift & Clutch Issues

• 🚗 The owner taught his wife to drive a manual transmission in the Cobra, noting that its low-end torque made it easier to learn on compared to a less powerful vehicle.
• ⚠️ The clutch began to smell when the car was pushed hard, prompting a return to the shop for inspection and repair.

Transmission and Clutch Removal

• 🛠️ To address the clutch and perform a rear cylinder head modification, the entire transmission needed to be removed.
• 💨 The process involved disconnecting electrical connectors, removing the exhaust system, drive shaft, and transmission mount before unbolting the T-56 transmission.
• 🔍 Upon removal, the stock clutch and pressure plate showed signs of significant heat spots, confirming the need for replacement.

Cylinder Head Cooling Modification

• 🌡️ A factory defect in rear cylinder head cooling was addressed by removing a freeze plug and installing a fitting to supply coolant to the hotter rear cylinders, aiming to prevent overheating.
• ⚠️ The process involved cutting and welding an EGR tube that was in the way, a task that proved challenging.

Rear Main Seal and Pilot Bearing Replacement

• ⚙️ While the transmission was out, the rear main seal and pilot bearing were replaced as preventative maintenance, despite being in good condition due to the car's low mileage.
• 🔧 A special tool and a freezing method were used for the pilot bearing installation, while a screw and pliers trick helped remove the old rear main seal.

Twin Disc Clutch Installation

• 🚀 A McLeod RST twin disc clutch was installed, offering double the surface area for an estimated 800 horsepower rating while maintaining a light pedal feel.
• 🔩 The installation involved a new flywheel, adapter ring, and careful torquing procedures using ARP bolts and specialized lubricants.

T-56 Transmission Internal Upgrade

• ⚡ The stock 10-spline input shaft in the T-56 transmission was replaced with a stronger 26-spline input shaft to handle more power.
• 🔧 This upgrade required internal transmission work, including removing the old input shaft and installing the new one with a new input shaft seal and bearing.
• ✅ The transmission's end play was measured and confirmed to be within specification before reassembly.

Shifter and Final Assembly

• 🕹️ A Silver Sport Transmission STX short throw shifter was installed, significantly improving the shifter's feel and positioning compared to the previous one.
• ⛽ The fuel filter, likely original, was replaced, revealing significant rust and contamination.
• 💨 The nitrous kit was removed, and the exhaust system was reinstalled, with a minor exhaust leak addressed.

Post-Installation Testing and Break-in

• 🚗 After reassembly, the car was started, and the new clutch and shifter were tested.
• ⚠️ The McLeod twin disc clutch requires a break-in period of approximately 500 clutch cycles to ensure proper engagement and longevity.
• 👍 The owner expressed satisfaction with the clutch and shifter, highlighting their performance and feel.