i was thinking about converting from auto to manual. what would be better, 4-speed manual? or 5-speed manual? what transmission should i use? what vehicle could i get one from? it would be for street use.
It depends on your intended use, rear gearing & engine combo. A big block with a lot of torque doesn't necessarily "need" the extra ratios that a 5 speed has. A 5 speed will get better mileage than a 4 speed IF it's an overdrive trans. A straight 5 speed won't offer any advantage in mileage, but would be better with numerically lower rear gears or with a smaller engine that likes to rev more.
For a driver imo you can "get by" with a 3.50:1 1st gear Saginaw and 2.29 gear... you can use a stock TH350 driveshaft and crossmember, just have to mount the linkage/pedals and cut a hole for the shifter. That would be a good cruising ratio, and will be geared similar to a 2004R with 3.42 gears. So long as you don't beat on the trans (power shifts, clutch dumps, etc.) it should hold up fine.
No, that T5 will have a 4.03:1 first gear and is weaker than the Saginaw. To use a 1993 and later T5, you will also need to find a bellhousing that bolts to a Chevrolet engine but has a Ford T5 mounting face. The only one I know of is from a 4-cylinder Jeep. You may also need to cut down the pilot on the input shaft as it will be too long.
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