91RS5speed

Recently finished swapping in a 1997 LT1 T56 into my 1991. Wanted to document the swap and prices for others. I read the sticky several times over the years by online170 and felt confident enough to do it myself. My T5 had begun to whine in 3rd gear and was starting to worry me. I watched craigslist and the forums for a bit and found one local on craigslist. The car had been in a wreck and the front and rear were smashed up with about 100k miles on it. List below on what I started with and what needed to be bought. I will add pictures and more information as I get it put together.

$750 Pulled from the 1997: Bought this in 2016 and it sat in my garage until the T5 lost 3rd gear in April 2019

LT1 T56
Bell housing /w slave spacer
shifter (had a t-handle shifter)
rubber stock mount (I was able to tear this in my hands)
4th gen cross member (would not work with 3rd gen)
used flywheel
used clutch and pressure plate (Be sure you get the pressure plate bolts they are unique for the LT1 pull style)
Clutch Dust Cover (looks the same as the 3rd gen)
steel driveshaft (did not need this was able to use my aluminum 3rd gen)
torque arm mount w/torque arm (ended up not using)
hydraulics got ruined while the trans was pulled

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Additional Purchases
$250 BMR transmission cross member w/ torque arm relocation
$22 RockAuto 109240 (10-9240) Dextron III ATF ( read about issue with running fluid other than Dextron)
$80-$90 New Flywheel LuK LFW282 Flywheel
$200 Summit New clutch and Pressure plate
$15 ebay Pigtails for reverse light, speedometer, and reverse lockout (should of got these from the car)
$30 polyurethane transmission mount (reused old from the T5)
$120 Rock Auto 4th gen hydraulics Master/Slave
$80 Dakota Digital SGI-5 (buffer box for speedo)
$50 T56 shifter boot (should have got this from the 97 the T5 is torn/disintegrating )
$12 Hawks 6 speed pattern sticker in yellow
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Optional
$160 ebay Pro 5.0 T56 shifter
$4 ACE hardware M20 1.5 plug for CAGS removal
$80 Harbor freight transmission jack (T56 is about 40-50 pounds more than the T5)
$5 Napa Bronze Pilot bushing
$20 Gunk and degreasers (I think the LT1 had a rear intake oil leak)

LT1/TA

That was a great deal you got on that trans and that was great that you already had it on hand.

I think that is a great list to help anyone on their swap,I know that info will be greatly appreciated.

How does your clutch work?
When I had my pedal down the clutch fork would rub the pressure plate.I had to use a spacer on the slave cylinder at first,then I installed a slave cylinder from an 89 cavalier(it has a bigger bore) it helps take up the extra fluid because of the 3rd gen clutch pedal travel.

How do you like it with the 305 and 3.42 gears?

91RS5speed

Clutch works great only have 120 miles on it so far though. The engagement point is higher than it was on the T5 though. No issues with the pressure plate rubbing so happy with that. Only issue I am having currently is the BMR cross member sits low and scrapes on everything. I am afraid I will end up having to swap it out. The 305 seems fine and can cruse in 5th and 6th at 70-80 without issues. I haven't beat on it yet since it has a new clutch. I am worried it might be slower due to the different gear ratios in the transmission and the additional weight but, will hit the track next season to test.

91RS5speed

Reserved for future info

8Mike9

So what was the issue with the 4th gen crossmember?
I'm doing this swap this winter and have a '97 I'm pulling parts from.

Corey1486

iTrader: (1)

When you used the cavalier slave did you remove the stock LT1 slave spacer or did you keep it?

LT1/TA

I know that my 94 formula had 3.42 gears and it kind of lugged on take off and in 6th.
I swapped in 4.10's and it made driving much easier to me,but my 88 sport coupe has 4.56 gears and it definitely does not lug.

LT1/TA

I kept the spacer.