The car is all back together now, it drives out great, and my Son is thrilled with the swap! What a difference going from a tired AOD to a 5-speed; like a different car. Basically, we pulled everything off the donor car and then restored all the parts. Essentially creating a 5-speed "swap kit". Once everything was ready, we planned a time to bring his car down when we both had enough time, and the weather looked like it was going to cooperate. It's been getting cold here in TX lately! At that point, we just staged his car, and started the stripping. It really helped to have the FSM at our fingertips, and plenty of the right tools.
One minor set-back that we encountered: I was hoping the wiring connector for the clutch position sensor was taped back on the original harness, but the connector wasn't there. This caused me to have to swap the dash harness out with the donor car. Luckily, the dash was out of both cars already. I weighed trying to cut the firewall openings with the dash in place, but decided it was easier to just pull the dash, as I've done it several times. Plus, it gave me the opportunity to give everything a good cleaning behind the dash, in the ducts, etc. The harness swap and cleaning cost me a couple of hours.
On the driveline, I used the differential as-is; just drained it, blasted and cleared the rear cover, cleaned up and used rust converter on the housing, and installed new half-shaft seals. I just cleaned, inspected, and refinished the RH "heavy" half shaft and used it as-is. There was strong evidence of a very recent transmission rebuild in the donor, so I just gave the trans an inspection, rebuilt the shifter, and cleaned it up. The clutch disk and pressure plate looked very good (compared them to an NOS one that I have), so I used them as-is also after cleaning it up. I blasted the driveshaft to bare metal, painted the assembly, and installed new U-joints. The master cylinder, hydraulic line, and slave cylinder checked out okay, so I reused them after cleaning. I installed a new pilot bearing (naturally), clutch release bearing, and rear engine main seal while I was in there. Everything else was just cleaned up, bead blasted, and refinished to look original. I used the trans and diff mounts from his car since it's low mileage, and they looked perfect. Before reassembly, I took a couple of hours to degrease and pressure wash the chassis and underside. Everything came out looking like new since it's always been a CA or TX car.
Here are a few photos of the project along the way: