zf conversion
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Senior User
Joined: Jul 2012
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zf conversion
alright so here's the deal i haven't done much research on it just wanted to see what you guys thought. i have a 95' powerstroke with the e4od and i want to put a zf5 or 6 in it what all do i have to do?
Cargo Master
Joined: Dec 2009
Posts: 3,452
Likes: 2
From: Santa Fe Tx
im not sure if the drive shaft it diffrent as far as lengeth but i do know a computer swap and wiring need to be changed as well as the starter, fly wheel, brake pedal assembly, mount a slave cyclinder clutch line cut a hole in the floor board ect ect its a P.I.T.A but its sooooooooooo worth it if you willing to do it if you do things right and bust your **** then in 2 to 3 days youll be done
Postmaster
Joined: May 2011
Posts: 3,447
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From: Monroe City in
There is two good write ups on here that i know of. I would post the links but im on my phone. Buckhammer, Tyler and Bill (rebilld) have done the swap. You dont have to change the starter. I do know that.
Hotshot
Joined: Jun 2007
Posts: 10,008
Likes: 7
From: Austin, TX
The starter between manual and auto on these 7.3s can be interchanged. So, no changing required.. On gassers though, it is required to change the starter on most of them.
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Hotshot
Joined: Jan 2012
Posts: 11,132
Likes: 3
From: Southern West Virginia
These are things you need from a manual truck to convert yours
Pedal assembly
Clutch master and slave cylinder
Clutch safety switch
PCM, or get your PCM flashed to manual
Steering column cover and key release swith
Center hump with shifter hole
Manual trans and t-case wiring harness
T-case shifter linkage bar
Cross member
Front and rear drive shafts, or have your rear drive shaft lengthened and the front one shortened
Flywheel, clutch and pressure plate
ZF5 transmission
The ZF trans is about 5" shorter than the E4OD. You need drive shafts from a manual truck with the same cab configuration and wheel base, or have your drive shafts modified.
Pedal assembly
Clutch master and slave cylinder
Clutch safety switch
PCM, or get your PCM flashed to manual
Steering column cover and key release swith
Center hump with shifter hole
Manual trans and t-case wiring harness
T-case shifter linkage bar
Cross member
Front and rear drive shafts, or have your rear drive shaft lengthened and the front one shortened
Flywheel, clutch and pressure plate
ZF5 transmission
The ZF trans is about 5" shorter than the E4OD. You need drive shafts from a manual truck with the same cab configuration and wheel base, or have your drive shafts modified.
PREMIUM SPONSOR
Joined: Sep 2003
Posts: 2,630
Likes: 217
From: North East Ohio
The best advice I can give is go find a donor truck that has EVERYTHING on it.
If you go buy a trans, pedals, and master/slave assembly, you're maybe 1/3 the way there.
There is a ton of little things that you will need.
Having a complete donor truck is the only way to go.
If you go buy a trans, pedals, and master/slave assembly, you're maybe 1/3 the way there.
There is a ton of little things that you will need.
Having a complete donor truck is the only way to go.
__________________
'96 7.3 F-350 Reg Cab 4x4 - bought new.
'04 6.0 E-350 custom 4x4
'08 6.4 F-550 Reg Cab 6 spd 4x4
'17 6.7 F-250 KR ccsb 4x4
'96 7.3 F-350 Reg Cab 4x4 - bought new.
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Hotshot
Joined: Jan 2012
Posts: 11,132
Likes: 3
From: Southern West Virginia
The best advice I can give is go find a donor truck that has EVERYTHING on it.
If you go buy a trans, pedals, and master/slave assembly, you're maybe 1/3 the way there.
There is a ton of little things that you will need.
Having a complete donor truck is the only way to go.
If you go buy a trans, pedals, and master/slave assembly, you're maybe 1/3 the way there.
There is a ton of little things that you will need.
Having a complete donor truck is the only way to go.
Cargo Master
Joined: Feb 2010
Posts: 2,526
Likes: 6
From: College Station, TX
These are things you need from a manual truck to convert yours
Pedal assembly
Clutch master and slave cylinder
Clutch safety switch
PCM, or get your PCM flashed to manual ****
Steering column cover and key release swith ****
Center hump with shifter hole
Manual trans and t-case wiring harness
T-case shifter linkage bar
Cross member
Front and rear drive shafts, or have your rear drive shaft lengthened and the front one shortened
Flywheel, clutch and pressure plate
ZF5 transmission
The ZF trans is about 5" shorter than the E4OD. You need drive shafts from a manual truck with the same cab configuration and wheel base, or have your drive shafts modified.
Pedal assembly
Clutch master and slave cylinder
Clutch safety switch
PCM, or get your PCM flashed to manual ****
Steering column cover and key release swith ****
Center hump with shifter hole
Manual trans and t-case wiring harness
T-case shifter linkage bar
Cross member
Front and rear drive shafts, or have your rear drive shaft lengthened and the front one shortened
Flywheel, clutch and pressure plate
ZF5 transmission
The ZF trans is about 5" shorter than the E4OD. You need drive shafts from a manual truck with the same cab configuration and wheel base, or have your drive shafts modified.
Also, for your 95 you will need a rear driveshaft from a truck the same cab configuration AND same t case. I believe the front section is different lengths between a 1356 and 4407 t case. The rear section is the same length from 94-97. Most of the 96s and 97s have 4407s but several guys have claimed 1356s in 96 trucks.
The best advice I can give is go find a donor truck that has EVERYTHING on it.
If you go buy a trans, pedals, and master/slave assembly, you're maybe 1/3 the way there.
There is a ton of little things that you will need.
Having a complete donor truck is the only way to go.
If you go buy a trans, pedals, and master/slave assembly, you're maybe 1/3 the way there.
There is a ton of little things that you will need.
Having a complete donor truck is the only way to go.
.Another option is find someone who has a manual and wants an auto.
Hotshot
Joined: Jan 2012
Posts: 11,132
Likes: 3
From: Southern West Virginia
Good info Jacob. I forgot about the different t-cases. We ran into that on Tyler's. He had a 4407 in his '97 and the donor was a '94 with a 1356. We just put the 1356 in his truck. Now were gonna take it all back out and put it in the cc he just bought, and put his ec back to an auto! LOL!!
Elder User
Joined: Jan 2012
Posts: 584
Likes: 0
From: Southern West Virginia
X4 on the donor truck!
Here's the link to my thread:
https://www.ford-trucks.com/forums/1...n-process.html
It's not really all that bad...if you have the donor truck. I think we had everything ripped off the donor in a day (except for a few little things we forgot at first), then it took us about a week of evenings to put the zf5 in and get everything working (backup lights require wiring harness modification, in order to key start requires wiring mods, cruise control required wiring mods...but they are not too bad. All the info is in my thread, and I made some wiring diagrams - they're in there too).
Like Bill said, we're getting ready to "undo" the swap in my ECLB and convert my CC I just got to a 5 speed, turning the ECLB back into an auto so I can sell it. I'll definitely be referencing what we did before...cause I can't remember exactly on some of the stuff! Man, I'm glad I did that write up now!
If you get into it and have concerns, just let us know.
Here's the link to my thread:
https://www.ford-trucks.com/forums/1...n-process.html
It's not really all that bad...if you have the donor truck. I think we had everything ripped off the donor in a day (except for a few little things we forgot at first), then it took us about a week of evenings to put the zf5 in and get everything working (backup lights require wiring harness modification, in order to key start requires wiring mods, cruise control required wiring mods...but they are not too bad. All the info is in my thread, and I made some wiring diagrams - they're in there too).
Like Bill said, we're getting ready to "undo" the swap in my ECLB and convert my CC I just got to a 5 speed, turning the ECLB back into an auto so I can sell it. I'll definitely be referencing what we did before...cause I can't remember exactly on some of the stuff! Man, I'm glad I did that write up now!
If you get into it and have concerns, just let us know.