I'm new to this forum and had some questions about a project a friend and I are going to start this coming weekend. He has a wrecked 1996 f-350 with a strong PSD with only 90,000 on the engine, and i have a 1994 f-250 with a bad 7.3 IDI turbo. We want to put the PSD in the 1994 in place of the IDI. I know there are big differences in the trucks, mainly the wiring. What else is likely to be a problem with this swap? Also, the wrecked truck had an auto, and the truck getting the PSD has a ZF5. Any help with this is appreciated.

 

I'd say it can be done, but like you said, the wiring would be the main thing. I'm not sure what all you'd need from the 96...probably all the harnesses are different.

Are you wanting to stay with the auto trans or use the ZF that was in the IDI? You can use the ZF - the bell housings are the same between the IDI and the powerstroke. The difference is the clutch/PP/flywheel. They are different from an IDI to a powerstroke. So if you wanted to use the ZF with the powerstroke, you'd need new clutch components, because the ones on the IDI won't fit on the 96.

You are probably going to have issues with the PCM as well. You won't be able to use the one from the 94, since it is an IDI. So that leaves you using the PCM from the 96, which is an auto. If you put it in (and use the zf), then you may end up with romping startups. Some have not, so it's a crapshoot.

I'm sure there are other considerations - these are just the first that come to my mind.

 

I think you can have the PCM reflashed. Some one smarter than me will chime in. I know it has been done before. Like Tyler said complete wiring harness from donor truck. Good luck and keep us posted on progress.

 

I knew i'd have to pull the whole harness from the 96, and we are going to use everything from the 96 as far as electricals go, even the fuel tanks and instrument cluster etc. But we are definately going to use the ZF instead of the auto, so thanks for the info about the clutch and flywheel. Someone told us we would have to change the firewall on the truck, anybody know for sure? thanks for all the help!

 

You're right that the '94 PCM won't work because there is NO PCM in an IDI truck with a manual trans. Nothing in the truck is computer controlled.

What I believe will work to make the PCM work with a manual is to remove the TRS from the driver's side of the automatic and leave it connected to the wiring harness. Make sure it is indicating neutral (there are two alignment marks that align when in neutral) and epoxy the center part of the TRS so that it stays in neutral. This will make the engine believe the trans is in neutral and it should start and idle fine.

 

They both have the same body. Do why not use the 94 to fix the wrecked one and do a trans swap. That would be a lot less work

 

^^^^^ Depends on how badly the F350 is "wrecked". BTW, are these both 4x4 trucks?

 

The 96 is a crew cab long bed, with no fixable body panels and the frame is bent. the 94 is an ex cab long bed, the only thing wrong is a cavitation hole in the #7 cylinder (322,000 miles) i got the 96 f350 for 100 bucks and the 94 f250 for 300. I would just swap bodies if they were the same and the 96 had a straight frame...as it is even if it costs a little money to put the Psd in the old truck, i will end up with a nice powerstroke for pretty cheap. and both are 4x4

 

And to Mark, thanks for the info on the tranny. I had a ford mechanic tell me the same thing today, so it sounds like a good plan

 

Man... two trucks for under $500!
Some guys have all the luck...

lol but congrats man...Sounds like a project!

 

D@mn, that's a shame about another CCLB getting taken off the road. Anyway, you could swap the front driveshaft and the whole front axle (swap the pitman arm as well) from the wreck to the '94, and have a de facto F350 ECLB. You'll need a driveshaft for an ECLB 4x4 manual, or perhaps you could pull the driveshaft from the wreck and have it shortened to ECLB 4x4 manual spec.

Pedal box and hydraulics from the wreck should work. Try to move the hydraulics as an assembly, hold the slave rod back with a zip-tie or the like, and keep the master above the slave at all times. This should avoid having to bleed the system after it's installed, or at least minimize the bleeding needed. Lots of other things you'll need from the donor - manual column cover, shifter, floor pan, etc., the "fig leaf" for the PRND21 on the dash, etc...

 

The ex cab has already had a d60 1 ton front end put under it, so the one from the wrecked truck will go under my 85 f250 and the turbo from the 7.3 idi will find a new home on the 6.9 that shakes my 85.

 

I don't think the swap will be that hard. With a complete donor truck you'll have everything you need.

 

That was my theory also. I think the hardest part would be pulling wiring harnesses without any damage, but even that shouldn't be too bad. i dont think its a project i'd tackle if i only had the engine, not a complete truck to work with

 

I didn't know when they started with PCMs...thanks for the info.