WOOOOOOOT!!! IT FITS!!!!
After sitting all winter in a snowbank, I pulled the 4t60 out of the olds just to make sure it was the wrong spline count on the shaft. The reason I thought the shafts were different is because 3 transmission shops said they wouldn't fit and so did the parts info at the auto stores. I thought I was screwed. NOT! I stuck the stub shaft from the 4t40 in there and it fits on both ends. All I have to do is get different seals. I did not have the time to check last year to see if it really would fit. Not only will the shafts fit in the transmission, but I can use the entire sub frame and weld/bolt it right to the bottom of the sunfire, saving LOADS of time, money, and parts.
This is going to be awesome! Maybe you can't tell, but I am stoked. This is going to be a LOT easier than I thought. If I would have known this in the first place, I would have pulled the entire unit out of the olds and stuck it in the sunfire and would have been driving it all winter. At least now the motor and transmission can get a good cleaning, paint, new seals/gaskets, and new fluid before going in.
The gearing will stay at 2.84 for the time being. I can always change it later.
I will use the dogbones from the caddy for upper torque mounts. That should keep things from moving around in there.
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1991 F-250:
4.9L, Mazda 5 speed, 4.10 10.25" rear
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