AODs Are Fun, Too
The good thing about having an AOD these days is that a bunch of companies have modified it inside and out, and complete high-performance transmissions, as well as parts, are readily available. Knowing that our slushbox was on borrowed time, we called TCI Automotive in Ashland, Missouri, and discussed our options with TCI's Stanley Poff.
Hollywood Combs uses a transmission jack to help with the installation. If you're doing this in yourgarage, you can use a fl oor jack. Just make sure you have a fl at surface against the transmission pan. | 
With The transmission bolted up, reconnect the throttle valve cable, shift cable, and any sensors. | 
We Also took the opportunity to replace our starter, as we noticed it was hanging wide open after starting the car. This unit is a high-torque piece from PA Performance. Because our car is a '92, we didn't need to use the additional solenoid wire that comes with the starter, as it's already wired for that type of starter. |
No Surprises here. Xenos installs our new Ford Racing Performance Parts aluminum driveshaft, which will save weight and reduce rotating mass- something the automatic-equipped Mustang already has plenty of. | 
Tci's Lightweight aluminum transmission cooler is installed in line with the factory setup for additional fl uid cooling and capacity. | 
TCI Supplies a male fitting for the radiator, and includes the proper hose for the connections to the stock lines. Transmission hose is different from vacuum tubing or fuel-line hose, so make sure you have the correct product. TCI includes it with its coolers. |
Since this is a street-driven Stang 90 percent of the time, we stayed conservative with our torque-converter stall speed. TCI offers its StreetFighter, which has a stall speed that is 1,500 rpm more than stock. But we opted for the Saturday Night Special stall converter (PN 432600), which is a lock-up-type converter that offers a modest 400- to 500-rpm increase in stall speed over stock.
The Cooler comes with plastic cable ties, which you run through the radiator and condenser. Going through both can be a bit diffi cult, but it's possible. If you can't get them through both, you'll need to pull the radiator.
TCI's StreetFighter AOD transmissions are fully remanufactured units that use only updated '88-'93 cores. All of the bushings, seal rings, and gaskets are replaced with quality OEM parts from Federal-Mogul and Clevite, while the steel and friction elements are replaced with new Kevlar-lined pieces. All of the bands and clutches are replaced with higher-performance versions, and the failure-prone, direct-drive input shaft isreplaced with TCI's heat-treated Vasco 300 high-performance version.
TCI also installs its own special pressure regulator spring to increase torque capacity. A Trans-Scat kit is installed for firmer shifts, and it also eliminates Third gear pressure cutback, which raises torque capacity in Third and Fourth gears. TCI offers both lock-up and non lock-up transmissions, and we chose the lock-up version for better economy.
Each transmission assembly is statically tested for individual hydraulic circuit integrity before valvebody installation, then dyno tested to verify proper functions, pressures, and cooler flow.
Our AOD (PN 431000) was also equipped with TCI's new constant-pressure valvebody, which prevents end users from burning up the transmissions due to improper throttle-valve cable adjustment. The T.V. cable still needs connection for proper transmission shifting, but the constant-pressure valvebody provides more freedom when setting part throttle shift points. Line pressure is fixed with no chance of encountering a low line-pressure condition, and the shift characteristics are greatly improved. TCI sells these separately if you want to install one in your own transmission.
With The transmission installed and the car on the lift, we took the opportunity to give it some fresh blood in the way of Pennzoil Platinum full synthetic oil. FRPP supplied the oil filter.
While we had the transmission out, it was a good time to replace the mount with a polyurethane piece from Energy Suspension. Part number 4.1124 netted the Energy Suspension motor and transmission-mount set, which fits '84-'95 5.0L Mustangs. Fox-body engine mounts are notorious for cracking and separating once the mileage starts adding up, so we replaced those as well. The Hyperflex performance polyurethane that Energy Suspension uses lasts far longer than rubber, handles more horsepower, and is more resistant to road salt, oil, and other contaminants that can wither factory rubber bushings.
While we weren't able to get to the track to see what kind of improvement the new TCI transmission and converter produced, we have driven it a bit on the street, and we can tell you the results are encouraging. Shifts are crisp, and the converter now flashes the engine rpm to about 2,500, which gets us into the nitrous oxide much quicker than before.
We can't wait to burn some rubber.