'68 Cougar upgrade to a 6 speed (6R80) Auto

[Gaugster]

Achieved a milestone today. After a bunch of rework to the tunnel and a little trimming of the transmission housing I was able to get the bell housing to sit on the adaptor dowel pins. Somewhat regrettably I had to make one access hole in the firewall for the passenger side top bell housing bolt. Aside from pulling the engine I couldn't think of any other option. It will be torqued to specification at least. More room on the driver's side which should allow for top side bolt access with the right wrench.

https://rumble.com/vc5u7n-6r80-automatic-retrofit-1968-mercury-cougar-390-fe-big-block-p5.html?mref=23gga&mrefc=8

https://rumble.com/vc5u3h-6r80-automatic-retrofit-1968-mercury-cougar-390-fe-big-block-p6.html?mref=23gga&mrefc=8

Here's some of the "carnage" to the firewall, tunnel and original cross member. Once I determine the pitch of the engine/transmission, u-joints pinion angle etc... I will know if more clearance and/or vibration isolation is needed.

[driveamerican]

When doing this type of conversion now do you check block to adapter alignment for center on the crank?

[Gaugster]

When doing this type of conversion now do you check block to adapter alignment for center on the crank?

The adapter that I purchased uses the blocks original alignment dowels. It's a tight fit and I just have to trust the quality of the kit. What I can control is the mating surfaces and I have wire brushed them down to be clean, rust and paint free.

[driveamerican]

Thanks I have done flywheel housings for trucks and once you do it the process isnt bad, at the same time I have never had a reason to check on a gas engine. So I was curious, I would think if you didn't have problems with the c6 you won't have trouble with the adapter. Good luck.

[Gaugster]

I worked out the design of the fluid cooling system. Very happy with the initial results. I made a mounting plate that replaces the factory splash shield. Need to finalize the 8AN hose routing and prepare some form of shield to protect it from road debris etc... I did a "candle test" and didn't burn the house down. 

Updated 2/5/21 - Added picture of the debris shield I am going to use. My local Lowes has leaf guards made of metal and painted black. Cut them into two sections and zip tied. A Keep It Simple Stupid (KISS) moment for sure.

https://rumble.com/vcjs83-6r80-automatic-retrofit-1968-mercury-cougar-390-fe-big-block-p7.html

[Gaugster]

In the past couple weeks I was able to finalize the installation of the 6 speed onto the 390. A solid "three clicks" to seat the torque converter. Also did the lion's share of the electrical in the engine bay. Next step will be the X-Member installation and benchmarking my engine angle options. Just a quick plug - I have had some in depth conversations with the people over at Stiffler's, Lokar and Power By the Hour. All of them have been awesome in support of my quest.

Here's the videos....

https://rumble.com/vcyvhl-6r80-automatic-retrofit-1968-mercury-cougar-390-fe-big-block-p8.html
https://rumble.com/vcyvn5-6r80-automatic-retrofit-1968-mercury-cougar-390-fe-big-block-p9.html
https://rumble.com/vcyvoj-6r80-automatic-retrofit-1968-mercury-cougar-390-fe-big-block-p10.html

[XxSlowpokexX]

Awesome. Going through this process on one of my other cars.  I was also really wanting to do the ten speed swap on that but no controller just yet.  I also just picked up a 64 galaxy with a 390 and this would be a great option in the future.  I don't however really want to be banging away at the trans tunnel though.  This is going to be night and day over that C6

[Gaugster]

Thanks for the complements. Yup, a little more metal work that I was hoping for but the end result will make it all worth it.

[Gaugster]

The transmission upgrade has been going well. It was a true pleasure to install the Stiffler's cross member. Up to now most of the work required considerable fabrication/trials but this puppy just bolted right in place. I can achieve between 2° - 4° of rearward engine slope. This should be fine but I won't know for sure until I source the drive shaft. It was a minor miracle that my exhaust cleared as is. Now I have been getting familiar with the Quick 6 controller and evaluating the throttle linkage/TPS setup. I am waiting for the Lokar Sport shifter and some cooling line fittings from PBH. Those should start showing up in the next couple of weeks. I think I have come up with a real slick way of mounting the Quick 6. It should be bitchin! Here's a video with some more detail on the TPS install.

https://rumble.com/vdgmkl-6r80-automatic-retrofit-1968-mercury-cougar-390-fe-big-block-p11.html

[Joey120373]

Great work! I will be following this project.

Hopefully, if a still have a job in the next few years, I will be putting a 6R80 in my 72 F250.
For now it’s motor first, then trans.

But the thought occurred to me a while back that just popping in a 6R80 behind the lackluster 360 that’s in it now would completely transform how the truck drives. That low first gear would really wake it up.

[Gaugster]

Great work! I will be following this project.

Hopefully, if a still have a job in the next few years, I will be putting a 6R80 in my 72 F250.
For now it’s motor first, then trans.

But the thought occurred to me a while back that just popping in a 6R80 behind the lackluster 360 that’s in it now would completely transform how the truck drives. That low first gear would really wake it up.

Thanks and good luck with your motor build! Yes I am hoping to greatly improved the drivability. My C6 failed so I went down this path. I am between jobs currently so this has kept me busy. I'll need two jobs for the motor I want to build.

[Joey120373]

I have been looking at used 6R89s, there appear to be 2 different bell housings.

Looking at your pics, I am assuming that you have to use a trans that came behind a 5.0 and not an eco-boost ? Looks to me like the top two bell housing bolts are spread farther apart on the v8 case.

Just wanted to verify before I bought a trans.

[Gaugster]

I have been looking at used 6R89s, there appear to be 2 different bell housings.

Looking at your pics, I am assuming that you have to use a trans that came behind a 5.0 and not an eco-boost ? Looks to me like the top two bell housing bolts are spread farther apart on the v8 case.

Just wanted to verify before I bought a trans.

That's correct. All the adaptors and supporting hardware/software are specific to the V8, 5.0L 6R80's. 2WD is ideal for car applications. 4WD trans could be used but the output shaft will need to be converted. Here's some info to help hone your search. 2011–2017 are the years to purchase from a Mustang or F-150/Expedition etc... 2015–2017 F-150 6R80's use an external cooler bypass. Best to avoid this if possible OR install the internal thermostatic bypass. IMO

[TimeWarpF100]

I have been looking at used 6R89s, there appear to be 2 different bell housings.

Looking at your pics, I am assuming that you have to use a trans that came behind a 5.0 and not an eco-boost ? Looks to me like the top two bell housing bolts are spread farther apart on the v8 case.

Just wanted to verify before I bought a trans.

That's correct. All the adaptors and supporting hardware/software are specific to the V8, 5.0L 6R80's. 2WD is ideal for car applications. 4WD trans could be used but the output shaft will need to be converted. Here's some info to help hone your search. 2011–2017 are the years to purchase from a Mustang or F-150/Expedition etc... 2015–2017 F-150 6R80's use an external cooler bypass. Best to avoid this if possible OR install the internal thermostatic bypass. IMO

I really like the 6R80 & installed them in 3 of my '66 Trucks (non fe) Now decided to try the 10R80 in current swap again non FE. The 10R80 is a monster and gotta be more than 2x the weight of the C6 and in height it is very tall. Got it to fit in the '66 short bed but quite close. Cant wait to try it out.

[Gaugster]

I have been looking at used 6R89s, there appear to be 2 different bell housings.

Looking at your pics, I am assuming that you have to use a trans that came behind a 5.0 and not an eco-boost ? Looks to me like the top two bell housing bolts are spread farther apart on the v8 case.

Just wanted to verify before I bought a trans.

That's correct. All the adaptors and supporting hardware/software are specific to the V8, 5.0L 6R80's. 2WD is ideal for car applications. 4WD trans could be used but the output shaft will need to be converted. Here's some info to help hone your search. 2011–2017 are the years to purchase from a Mustang or F-150/Expedition etc... 2015–2017 F-150 6R80's use an external cooler bypass. Best to avoid this if possible OR install the internal thermostatic bypass. IMO

I really like the 6R80 & installed them in 3 of my '66 Trucks (non fe) Now decided to try the 10R80 in current swap again non FE. The 10R80 is a monster and gotta be more than 2x the weight of the C6 and in height it is very tall. Got it to fit in the '66 short bed but quite close. Cant wait to try it out.

How's the aftermarket for the 10R80? I know that US Shift has been working on developing a controller for it. Personally I haven't checked about OEM computers since you typically need to a modern trans and engine. What to the shifter options for the 10 speed look like?