I did a sqp from the dual mass flywheel to the single mass flywheel i have noticed some gear noise but nothing to excessive i went thru LUK for my flywheel and clutch set it is not a hard swap to do at all

 

that sounds about right (the gear noise at low speeds) i have a few friends that work at LUK clutches in wooster ohio which is 20 minutes from me, and i got the whole kit at their cost.

 

I really wish I knew why some guys are having trouble with these conversions. It doesn't make any sense......

 

Im one of those guys having major trouble with the conversion. I recently swapped my DMF for a Southbend SMF and the first time i started the truck after installing the clutch i had my dad, bro, and some friends standing beside the truck and nobody could hear anybody else talking it was so bad. Ive had 2 other mechanics look at the truck and they have no idea what is causing the noise...but i do know for sure its coming from the tranny. It was so bad that i actually refused to drive the truck(and i absolutely love my truck). Since im currently going to school for my 2nd Year Heavy Duty Mech. I cant afford to put any more money into the truck so i was forced to park the thing and am now driving a 1998 Cavalier.

Ive recently used a stethoscope to listen for the noise in the tranny and its alot louder on the Pass side PTO cover. So one day when im not too pissed at the truck im planning on pulling the PTO covers and feeling around in the tranny and see if i can see any internal damage that would be causing the noise.

At this point im not sure what im going to do with the truck. The idea of parting it out or selling it has popped into my head many times. Or im going to just leave it until i get out of school and get back to work so i can rebuild the tranny and see what happens. Or im going to pull the motor and tranny after im done school and put in a cummins motor with either a rebuild ZF5 or a completely different tranny.

 

If you put in a Cummins you might as well put in an NV4500.

 

Was thinking the same thing

 

Well we ended up ordering a new from ford oil cooler for 411.00 and it doesn't even come with the O-rings.... So I had to go back today again to order the O-rings and gaskets. I got the new oilpan in and new rear main seal. I painted the new oil cooler to try and prolong the rust a bit this time. Ford garage told me the O-ring will be in tomorrow morning so I should be able to press that back together and throw it in. Than I can finally bolt the motor back down and install all the flywheel and clutch junk. New U-joints, brake all around, brake lines, and fluids and this truck will be on the road again hopefully.

Since the tranny is out I figured its a good time to change the tranny and transfer case fluids. I have been thinking of running a full synthetic oil in both to try for some better mileage. Any input on anyone that ran synthetic in ford ZF trannies? Good, bad, no change?

 

is that price just the center section of the oil cooler ?

 

If you got the cooler bundle from Ford for 411 dollars, you stole it.

Granted it has been a couple years since I priced one, but the last price I was quoted was 900 for the bundle.

The rear header was something like 350.

I would get some of my parts from International, but the closest dealer is over an hour away.

 

that was just for the center section and dealer cost. retail for walk in customers is 520.

I picked up the O-rings and gaskets today for 40.00. Cleaned everything up and pressed it all together. If I have time tomorrow I will locktite the plugs back in and get in back in the truck.

 

I'm not sure if something has changed recently at ford's HQ, but I've noticed that prices seem to be getting more reasonable at the dealer for parts lately. Good enough that I only use motorcraft oil filters now (powerstroke style naturally).

 

junk the dmf setup. LUK makes a conversion kit that is a 12" clutch disk. the stock dmf is only 11". i have a 94 idi turbo. with the mods that i have i was blowing the springs out of the clutch disk. the conversion does however make more noise at low speeds but that is due to the high torque spikes the idi has. i have almost 12000 miles on the conversion and have not had a problem yet.

 

success! No leaks anywhere and the clutch/flywheel setup works great! Like people have mentioned a very very little noise at idle and low low speeds but other than that perfect! Softer pedal than stock and no more chattering.

Sorry still haven't written down the part numbers yet to post them up. I'll get on that.

 

Now that you mention it, I after the conversion remember a lighter pedal on that powerstroke that I worked on too.

 

Man the pedal on my '94 DMF is STIFF!!!
I about puch the pedal through the firewall on my Dodge when I go to drive it.
My '90 gasser with a ZF-5 isn't as stiff either. Is it a DMF too?