All righty then, my 87 250 came with a 6.9 and c6 and it was awfull on the hwy so I decided a swap was in order this will probably be over the coarse of a week or 2 because its hot and Im lazy.
I went to the junk yard and found a 89 7.3 with 39,000 miles. I got the trans, pedals,clutch,flywheel I had to buy new the slave,master and line.[IMG][/IMG]
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Today I started on the pedals and got everything switched out. I wanted to install the master cylinder but there was no holes for it liked I had hoped so what have poeple done to fix this. It looks like there are dimples where the holes go. What size hole saw are you using? I do not want to cut away to much.[IMG][/IMG]

 

I got a couple of ??s. What does the vacum switch do on the brake pedal? My donor did not have one. Do I need it?

It looks like I will be doing alot more than a tranny swap in this pig.I really should have looked it over better but oh well

I pulled the radiator to get it rodded but when I got it out it looks pretty bad on the upper engine side. I am going to see what the radiator shop sais tomorrow.
Then I saw why the A/c is empty, the condenseris leaking so here goes some more $$.
I need to order it so I can put it in before a put the radiator back in. So I went to break the A/c sytem down because I might as well do it all if Im doing it. Tried to remove the orfice tube and of coarse it was frozen in there and ripped so now I have to get an evaporator also.

This truck will be new when I finish all this crap. I hope I like it because I will have it for a while lol

I was also looking to replace the T stat and it looks like you have to remove the air pump. Is that how its done? Can I throw the pump in the trash?

 

what "air pump" are you taking about?
i have never seen an air pump on one of these engines in a pickup.

 

., just went and looked and its a vacum pump that goes to the booster. I have worked on some power strokes and they have a 12v vacum pump so i guess I figured they all did.

I am new to diesel and really new to old trucks. I never worked on anything that did not have FI at the dealership so bear with me and my some time stupid questions lol.


So what about the vacum switch on the brake pedal?

 

not sure. i know on the 88 the cruise shut off is electric. maybe the 87 was vacuum

 

That would make sense. I will have to try to find a vacum diagram and look at the cruise unit

 

Im peretty sure the vacuum one is for cruise also. my 89 had that for the cruise control.
i just got done with a very similar swap last week, went from an e4od to a zf 5 speed.

I didnt have to take off any of my dash to get my pedals in though.

Rob

 

It was just easier and 5 min extra to pull the column. Im glad I pulled it now it will make it easier to drill the holes for the clutch master.

 

ya sounds like u got the short end of that stick, mine had the plate that i just had to unbolt and bolt in my master.

good luck with your install!
Rob

 

I was kicking around the junk yard today and found an 86 custom like mine but it has a differnt manual trans. Does any one know if the drive shafts are the same for the zf5 and the 4 speed tranny?

I am trying to get buy with with out having to have my shaft modded.

 

Okay,I got alot done this weekend but for got pics. I think Im ready to start her up but I dont know which 2 wires I need to connect at the mlp switch..

I thought I read some where it was the white with red strips and the other 2 go to the reverse switch. Is this right?

 

I need some help. I am dealing with the dreaded clutch bleeding now and am trying the hold it in for 5 min at a time and it seems to be working.

I cant drive it yet because I still have to get the drive shaft made so Im hoping it will beed the rest of the way when i drive it.
My question is ,I am leaving the strap on the new slave and its supposed to break when the clutch pumps up right?

 

Yes the strap should break, or pop out of the retaining slots.

 

I added the fluid today and bolted in the shifter but I have an awfull lot of slop in the gear shifter in all gears. I would say a good 4 inches.

Am I missing something? for some reason I thought that there were nylon cups that the shifter bars set on but I may be thinking of something else. My does not have these cups and it doesnt look the slots are worn.

FYI I have not started it yet and engaged the tranny. I dont know if that matters but thought I would mention it.

 

No, it's good that you do mention it. Something doesn't sound at all right, and the transmission could be locked with more than one gear engaged if the shifter is improperly installed. I've rebuilt several manual gearboxes but admit that I am not intimately familiar with the ZF gearboxes (yet, I have to tear into mine to replace a noisy bearing) so any experts feel free to chime in and correct me on this one.