I have a 94 F-250 4X4 with the E40D trany and 5.8L eng. It's starting to slightly buck when driving so I think the trany is getting ready to crap itself. It got 120K on it and the last 30K i put on weren't exactly easy. I can score an 87-92 style 2wd f-250 fleet truck from the company my buddy works for for 250 bucks. All their trucks have sticks in them and they have a couple dozen of em so i got a pretty good pick of the crop. Can i get some advice on these questions?
1. will i need an adapter to get the transfercase to bolt up?
2. what will happen with the computer since the truck was and auto?
3. will driveshafts need lengthen/shortened?
4. crossmember?
5. how do pedels mount
6.I know where the clutch resivor should go, there is a block-off plate on firewall, will hydrolic lines be a straightforward instalation.

Im pretty mechanical savy, my dad works for napa and two of my budies are fabricators so if i have the knowledge i should be able to tackel this.

Any help will be appriciated.

I have to get rid of the slush box i hate it

 

it is a strait forward conversion though there is one problem i see already, the 2wd tranny will not work the tail housings and main shafts are different, but you can use it as a score and get a rebuild with the proper setup. As to pedals they bolt right in place of your single brake pedal using the same bracket. you will have to trace you nuetral start and plumb it into the swith on your clutch. dont hard wire it in as it will burn your computer up or at least mine did. your floor pan should be changed oor you can hack the hole into it. the hydolic lines all clip into place, on my 96 the clip were there and i just had to put it in em. the computer should work, mine did ill i went to the five speed mass air computer. the tranny is shorter but the holes are already in your frame. I think on a regular cab the same cross member will work but on ext cabs the coss member is a single bolt flat unit versus the drop cross member used on the e4od also the zf is consideribly shorter so be prepared to do both the front and read drivelines.

Good luck
Dusty

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Why Buy new when you can build and tailor it cheaper?
(updated) F-350 4x4 ext cab Short Bed Green Monster, it is now Sporting a 300HP 715lb/ft Dyno rated 5.9L 12v Cummins diesel now w/ NV5600 6 spd and custom NP205 ford T-case w/ rear spicer 1410 yoke, 3.55 gears using the 41 spline pinion and 1410 U-Joints, Power-Lok equipt Dana 60 front and posi rear, 315/75's on 16x8" Outlaw II's. (Used to have)205000 miles, Mass air 460 w/ performance heads and a E40d to 5spd conversion and Doug Thorleys. Old EFI 460 @10 MPG to the 12 V @ 23.2 MPG @ 75 MPH and loving it.
My other toy is a '69 CJ-5 354 Hemi 4 spd 4.88's 32x12.50 MThompsons w/ power-lok 44 rear.

 

So the transfer case will not just bolt in place of the tail shaft? The output shafts are different sizes? Whats the diff between mas air and mas speed computer? I'll have the entire 2wd truck will the computer work from that as long as its the same motor? Can i just eliminate the nutral start switch.

Thanxs for the info so far. Im confident i can do this.

 

Also make sure you get a 11inch clutch and assembly...the M5OD came with 10 and 11inch clutch/assemblies and that 1 inch difference is like night and day when putting that tranny with that engine.
Good Luck

 

Update on the swap.

I now this guy who has all the parts. The 5 speed he was gona find me, the owner wants 1500 for everything. But this guy has everything to drop the 4speed from an 89 3/4 ton. It's gona cost 1000 plus a new clutch. Which he priced for me at 120-130 bucks. He told me the 4 speed will have almost the same gears as my auto.

 

Contact havack@broncodata.com . I recently helped him do this to his '93 Bronco (with a '90 Mazda M5OD) and he's working on putting the writeup on his site. It may be there already. He's often on the Off-Road.com BBS.

 

A 4spd manual from a truck will not have an overdrive such as your 4spd auto does, unless it is a 4spd with 4th gear OD from a 1/2 ton truck which as I understand it is a very less than desirable trans.

 

[updated:LAST EDITED ON 04-Nov-02 AT 08:27 AM (EST)]The Mazda M5ODR2 and ZF S5-42/S5-47 are all good manual 5sp OD transmissions. The ZFs have a granny gear & PTO plates.

 

Ok i talked to the guy last night. The tranny is a 4 speed with granny gear out of an 89 3/4 ton. He has the comp for the swap. We took some measurements and i think the overall lingth will not differ much from stock. If it does, he has the driveshafts too and i located the extra holes in the frame to move the cross menber up. We are using my transfer case. he got a stick steering column to put in it too. he has done this swap befor and said it's no problem. the only thing we need it a flyweel and the new clutch. I'll let everyone know how it went after im rowing the gears.

 

You don't need a new column - all you have to do is remove the clips that hold the auto shifter on YOUR column and buy a $16 upper column cover with NO shifter hole. Check havack's site - he has all the info there. http://www.broncodata.com

 

Changing the column isn't that big a deal he is just trowing it into the deal.

 

Can any of you guys tell me what the difference in gear ratios is gona be between the e40d and the 435 4 speed. right know i can cruse at 70 mph at 1800 to 1900 rpm with a 285 size tire. My tires pretty much limit me from driveing any faster than that. I noticed going from a 305 to a 285 my rpm went up about 200 rpm.. Also someone had mentioned that i'd need to change starters and the wireing. I can understand that the starter may be differnt but how is the wireing diff? . the auto is really getin bad lately. Anybody know where i can get an aftermarket shifter for the 4 speed. i think the hurst shifters are so awsome looking. and my truck would look good with one. I allready bought the tee handle for it.

Just draemin about bangin some gears

 

Check havack's site - http://www.broncodata.com . He has lots of info like gearing in various transmissions, and his writeup of the E4OD to M5OD swap includes info on wiring changes.