Well, I've been cruising all the Powerjoke forums and I can not find precisely how to complete a manual conversion to my truck.

First, what I have: 1997 F-350 PSD 4x4 single cab with e40d.

I also have a donor truck that was wrecked that was a: 1989 F-350 IDI 4x4 with a ZF-5.

The IDI was my previous truck before it got hit by a person running a red light. Truck ws mint with 100,2xx miles.

So before I go selling the trans, what would entail to swap the zf-5 to replace my stupid e40d? I have the whole parts truck still and everything from pedals/trans/drive shafts and all is good. Only thing damaged was the transfer case but I read both auto and manual use the same t-case? I would be considering an aftermarket clutch and flywheel from Valair.

So whats everything I need and how would I complete this swap before I sell my zf-5 and kick myself in the butt!!??

 

You will need a pedal assembly from a '92-'97 truck, gas or diesel doesn't matter. The flywheel and clutch from the IDI will not work, so you will have to get that, and like you said, I recommend Valair. As far as the drive shafts, you will have to get your rear lengthened 5 3/8", and your front shortened 5 3/8". The t-case in your '97 should be a 4407 and it uses a flange style yoke for the rear drive shaft. The '89 is probably a 1356 t-case with a slip yoke, so the drive shafts will not work. I can't remember if the clutch master cylinder and interlock switch is the same on the '88-'91 trucks or not. You may want to get those from a '92-'97 truck just to be safe. You will have to change the trans wiring harness, and I don't know if the '89 plug up on the driver's side fender well will be the same, you can look at that and see. Your PCM will more than likely need to be flashed for manual, or you may get the "romp" at start up. A PCM from any '94.5-'97 PSD manual truck will work. There will be a couple wiring changes you will have to make also. The trans, cross member, center floor pan with the shifter whole, and possibly the clutch master cylinder is what you can use from the IDI truck. Oh, and if you use your t-case with the ZF, you will need to find the t-case shifter linkage bar from a ZF/4407 truck, or make one to fit yours. I hope this helps.

Here is a link to the thread where me and my son-in-law did his swap, and we've done a couple since then.https://www.ford-trucks.com/forums/1...n-process.html

 

Absolutely! I have read most of this but from different sources and no one was really certain on such of the composition. Thank you so much!

 

It's not a bad swap to do. I'll help you any way I can if you run in to problems.