OK, to keep it somewhat simple. 2001 F150 4x4--102,000 miles(yep). 4.6L, Manual Trans. 3.08 Axle Ratio. Very solid truck, only thing replaced was MAF at 99,000 and truck has common odometer/panel lights/gauges issues. Little hauling or towing, 50/50 town/highway, 4x4 all winter plus some off-roading. Problems as I see things. Weak(my opinion) Clutch from day it was new (easy to slip clutch; tall gears, or weak clutch design?). Not enough low rpm torque(engine or tall gears, or both?). Sloppy(my opinion) shifter. Weak Transmission (Internet Rumors??). Possible Fixes. Stronger Clutch. 3.55 Axles (many truck-only junkyards here). Trans Swap (suggestions?--NO automatics). Superchips Flashpaq. Intake Upgrade(type?). Underdrive Pulleys. Electric Fan. Headers & Exhaust. Someone who has done some or all of these please come forth with issues/problems with this and effective fixes. Please, no rumors or hype. Thanks, Sean..........(I tried to format this in an easy to read list, but the page bunches it all up no matter what I try)

 

well the gear ratio is not helping the lauch , the 3:08 is a bit on the low side, you'll definitely be happier with 3:55 and up (3:73 or 4:10 is better), especially if you tow at all. that all plays into how hard the clutch gets used, which adds to the strain through out the drive line.

the taller gears come at a price though...you probably loose MPGS

give this a look see 1983 Ford Bronco Diagrams picture | SuperMotors.net

 

e&b, thanks for the reply. I mainly chose 3.55 because that's the other option of gear ration that my truck could have had and I'm really wanting to stick with bolt-on mods. I wasn't sure if similar year models with 3.73 needed modifications or not. I'm not really worried about mpg because it's a 4x4 truck and it only gets 17mpg on the highway now. My questions about the trans swap was mainly: 1). Is the M5R2 weak? 2). What other 5-speeds will bolt up to a 4.6L? Also, how do I get my posts to stay in the layout I type them in? The bunched up paragraphs is even hard for me to read!

 

gears are gears...should be able to get any set you need/want. If your thinking of swapping whole rear ends from the salvage yard....then yeah, the 3:55 ratio might hold more possibilities as to a easier find from a popularity stand point.

Just keep in mind...whatever ratio you get/find...make it X2...for both front and rear.

as to the manual tranny & well as the clutch...go talk to a reputable transmission repair place place near you...they would have a good understanding as to what would be stronger or weaker and stand the type of abuse you're going to give it. you might able to rebuild yours into a heavier unit?

as to the typing & keeping it from "bunching"
within the text box as you reply or post...just press (enter) {twice} on the key board.

to break into a new line & add separation.

you'll have to click on the submit reply tab on the bottom of the screen to post anyway. play with it...you'll figure it out.

 

Thanks,I am thinking of rear axle and front center sections from a junkyard, because it is cheaper that way than new gearsets. They can be rebuilt reasonably cheaply as there is an axle shop here. The transmission is the main issue. There are no "reliable" transmission shops within reasonable driving range here. Also, I've read many internet posts stating that the M5R2 can't handle any real torque or towing/hauling(True or False?). Thus my question as to there being another model of 5-speed that will bolt up to a 4.6L(perhaps with an adapter plate). I don't intend to use the truck like an F350, but I don't want to tear the tranny out with occasional work and play either. A tighter shifter would be nice as well. The clutch I know is weak, it has been since the truck was new. I've always had to be careful of how/where I pull out so as to not slip the clutch. Ford replaced it under warranty in 2002, but the new one was/is identical to the first one. I have yet to locate a stronger rating clutch. I "thought" that a HP Mustang clutch would work, but apparently there are several differences(bolt pattern, etc.). Perhaps the lower gears will "help", but I doubt it will cure this. I've pretty much settled on the power adders and exhaust, but I'm not even going to bother unless I can get the above things fixed. Once again, nothing I seem to do allows me to post a reply in the same style I typed it. Also, none of the smileys or font buttons work. Sorry for the mess.

 

Sounds like you need a Centerforce clutch I never had a problem with my Luk clutch, couldn't afford the Centerforce, lol. The tranny isn't bad, just don't rag on it. I never had a problem with mine, and I towed/hauled with it a lot! As far as the sloppy shifter goes, there's a pin near the pivot ball that prob needs to be replaced. As it wears down, the shifter gets sloppy. Make sure you either put RTV on those 3 rubber plugs, or put freeze plugs on top of the tranny where the shift rails go in. They'll pop out due to age, and dump all your tranny fluid out while you're driving.

 

Centerforce? Yep, a lot of money. I'll look at Luk, I've never heard of them. The autoshops around here only carry factory the factory replacement for mine. I'm simply tired of being afraid to pull out uphill. If the M5R2 will handle some towing, it will handle what I will put it through. I will also try the shifter fix. As long as it will tighten up, that should be good.

 

Luk is a good brand, and not expensive either. If you split the tranny and engine, go ahead and replace the throwout bearing/slave cylinder. Get one with a lifetime warranty from a parts store, as they tend to start leaking after a while, then you can just replace it for free . I've towed 4-5k pounds with mine plenty of times, never had an issue.

 

Thanks, you actually answered the questions.

I've done a few clutches and always do throwout, pilot bearing, and on the newer stuff the slave cylinder. I also usually have the flywheel inspected/surfaced. If/when the M5R2 fails I'll worry about it then.

I found a 2000 model 3.73 rear axle and front center section with 41,000 miles on them(no rebuild needed!). I'll rebuild the front end when I do the work. The 3.73 "shouldn't" be too low for the highway behind a 5-speed.

I've settled on the following power-adders:

Superchips Flashpaq
Custom Fab(me) True CAI(through the grille) w/ K&N
JBA CatForward SS Shorty Headers
2 1/2" Exhaust (Can't decide on muffler, the Super 44 on it now sounds excellent but it only lasted 3 years...suggestions?)

And...I figured out my posting issues. My Firefox add-ons were doing their jobs a little too well.