I have a rusted out 1988 F350 4x4 with a c6 and 460 in it. I want to swap the engine into another truck along with the Tx case but want to switch to a 5 speed manual.
My question can a 5 speed F250 tranny that is 2x4 be converted to bolt up to the 4x4 transfer case? I am guessing I can get a rear housing of a 4x4 ZF tranny and swap it over but havent looked at them. I am hoping that someone else here has already done a swap like this and can share their knowledge. also is the Bellhousing different on the 351, the 460 and the diesel engine ZF trannnys?
thanks
DJ

 

The big block bellhousing is unique, the 351/300 ZF will not fit. Also, the 2wd version is quite difficult to change over to 4wd, unless you've got a divorced transfer case. To make the switch financially viable, you need to find a big block 4wd ZF.

 

Other thought is going with an AOD, are the 2wd and 4wd AOD's different in bolting up to transfer case or can I use a 2wd AOD pretty easy

 

You haven't told us what transfer case you have. From my limited experience it looks like Ford uses a standard 6 bolt arrangement to mate the transfer case/tranny tailshaft. My understanding is that Ford did not put the AOD behind 351s in trucks because it would not hold up. It would be an even worse choice behind a 460. To paraphrase Cheggie, the big block bellhousing is unique, the 351/300 AOD will not fit. Also, the 2wd version is quite difficult to change over to 4wd, unless you've got a divorced transfer case. At the least you would need the AOD 4X4 tailshaft housing.

Ford used the E4OD in those vehicles where it needed an automatic overdrive transmission and it came from the factory with the 460 engine. The E4OD automatic would have some issues of its own. It is controlled by the ECU as well as inputs from the the TPS and VSS and other sensors. You would need to have the proper computer (or an aftermarket transmission control unit) for an E4OD and hook up all the sensors and related wiring.

I know we're all trying to work with what we have on hand but you should try to get the proper 4X4 transmission to start out with. I'm sure that for less than the cost of one automatic transmission rebuild you could get a big-block ZF 4X4 transmission and the related components to do a manual transmission swap. It will save a lot of headaches and $$$ in the long run. Be aware that all these transmissions have different overall lengths and that may require changes in your driveshaft length.

Here is a link to a recent thread where a guy talks about doing an automatic to ZF conversion:
https://www.ford-trucks.com/forums/539722-zf5.html

Another link with a manual Mazda trans to ZF conversion:
https://www.ford-trucks.com/forums/1...F+torque+specs