First of all I want to say THANK YOU to everyone that has helped me by sharing your knowledge. redman84, ReBilld, TyBragg, FI460, 91 Dually, BuckHammer, and everybody else I can't remember by name. The information and knowledge you have shared has been incredibly helpful and made this process go so smoothly for me.

For those interested in the back story on the automatic you can check out the thread i made about it here: https://www.ford-trucks.com/forums/1...converter.html

I drove the truck for the first time yesterday as a manual and it's is like a totally different truck. Stock auto to stock manual is already a big difference but going from sluggish mystery problem POS auto to 60hp econo tuned manual is like night and day.

Almost everything is buttoned up. I just need to run the jumper wire down the steering column to clutch position switch and then I can put the column cover and dash trim back on. I also need to make something for the "inner boot" for the shifter so theres not so much noise coming in through the floor.

For those considering the swap, DO IT!!!!!! All in all its not too bad of a project. It's a lot of little things that add up to make quite a bit of work but most everything is very straight forward. Sourcing the parts if you don't have a parts truck is definitely the hardest part. (also getting the transfer case linkage on and off is a total PITA)

I will compile some part numbers and info about what I used and create as thorough of a list as I can and will put that in this thread later.

I took about 200 pictures of the project so what I plan on doing is just posting some of the highlights here and if anybody has something specific they want to see just ask and I'll post it. Also I will be uploading all of the pictures to facebook and I will make the album public so anybody can view it but feel free to "friend" me if you want.


Ended up going with a rebuilt because the 2-3 synchro hub and 3rd gear were trashed in the donor trans i picked up. I started pricing out everything i needed plus the rebuild kit and it made more sense to get a professionally rebuilt unit with a warranty and some piece of mind.
<a href="http://www.flickr.com/photos/100332056@N08/9508808873/" title="IMG_0442 by kellenscarla, on Flickr"><img src="http://farm4.staticflickr.com/3689/9508808873_b4684930da.jpg" width="500" height="375" alt="IMG_0442"></a>

<a href="http://www.flickr.com/photos/100332056@N08/9508808349/" title="IMG_0474 by kellenscarla, on Flickr"><img src="http://farm6.staticflickr.com/5531/9508808349_5697359888.jpg" width="375" height="500" alt="IMG_0474"></a>


<a href="http://www.flickr.com/photos/100332056@N08/9511600520/" title="IMG_0487 by kellenscarla, on Flickr"><img src="http://farm6.staticflickr.com/5550/9511600520_a47a7d4c4e.jpg" width="500" height="375" alt="IMG_0487"></a>

<a href="http://www.flickr.com/photos/100332056@N08/9511600136/" title="IMG_0497 by kellenscarla, on Flickr"><img src="http://farm6.staticflickr.com/5526/9511600136_825715c2ab.jpg" width="500" height="375" alt="IMG_0497"></a>

<a href="http://www.flickr.com/photos/100332056@N08/9508807359/" title="IMG_0500 by kellenscarla, on Flickr"><img src="http://farm8.staticflickr.com/7332/9508807359_7af85cb680.jpg" width="375" height="500" alt="IMG_0500"></a>

<a href="http://www.flickr.com/photos/100332056@N08/9508806993/" title="IMG_0506 by kellenscarla, on Flickr"><img src="http://farm4.staticflickr.com/3832/9508806993_c1c1f526a9.jpg" width="500" height="375" alt="IMG_0506"></a>

<a href="http://www.flickr.com/photos/100332056@N08/9511602550/" title="IMG_0512 by kellenscarla, on Flickr"><img src="http://farm8.staticflickr.com/7349/9511602550_bdd4659a68.jpg" width="500" height="375" alt="IMG_0512"></a>

<a href="http://www.flickr.com/photos/100332056@N08/9508812417/" title="IMG_0700 by kellenscarla, on Flickr"><img src="http://farm4.staticflickr.com/3666/9508812417_cf98d067e3.jpg" width="500" height="375" alt="IMG_0700"></a>

<a href="http://www.flickr.com/photos/100332056@N08/9508803327/" title="IMG_0720 by kellenscarla, on Flickr"><img src="http://farm8.staticflickr.com/7391/9508803327_770523955d.jpg" width="500" height="375" alt="IMG_0720"></a>

<a href="http://www.flickr.com/photos/100332056@N08/9508802837/" title="IMG_0721 by kellenscarla, on Flickr"><img src="http://farm6.staticflickr.com/5340/9508802837_1d3767e447.jpg" width="375" height="500" alt="IMG_0721"></a>

<a href="http://www.flickr.com/photos/100332056@N08/9508802203/" title="IMG_0727 by kellenscarla, on Flickr"><img src="http://farm3.staticflickr.com/2819/9508802203_24ea2d1842.jpg" width="375" height="500" alt="IMG_0727"></a>

 

hey man - great pics and great write-up. i'll be all over that parts list and 200 pics when you post them as i'm planning on digging into my swap in the coming month or so.

that's also one heck of a clean truck you have there!

by the wya - what kid of shifter is that you ahve there. definitely not a stock one...

 

Great pictures! That facebook album will be nice. We don't have a fully documented swap thread with pictures. Each of us just kind of posted the big parts and the parts we had trouble with.

I used a C-Clamp and socket to get my transfer case linkage on. Worked great. Your fabbed one looks good.

Best interior color btw .

On edit: Wiring?
Did your ZF-5 wiring harness require any modifications? Mine did not. The pins were in the correct place and appeared to have never been moved. My theory was that every other time we've seen this swap happen it was a ZF-42 into a truck that would have come from the factory with a 47. I think 47 trans to 47 truck should match up. Was I right?

 

Thanks for the comments and yes I agree it's the best interior color. Although grey and black is pretty nice too.

You are correct! Didn't have to modify the harness at all. It was from a S5-47 out of another 97.

The shift **** is an 18 speed eaton fuller type. I didn't have a **** and I hate the stupid splined ford ***** so i cut the spline portion off and tapped the the stick 1/2-13. Then i just slid some conduit over it and tacked it in place so the big **** wouldn't look stupid sitting on top of a thin stick. You'll see in the fb pics which will be up sometime this evening.

 

Hopefully this works.
Link to the facebook album. I'll be adding more pictures in the coming days.
https://www.facebook.com/media/set/?...1&l=af98abf5a0

 

I do like the shifter you use. I just got done with my swap as well, but had no shifter at all.. So I used a baseball bat for now. I wouldn't mind having a semi truck shifter though

 

Yeah I saw your baseball bat shifter. Pretty cool and a good idea. Since I already had the stick but no ****, the big rig shifter was a no brainer for me. They are the most comfortable shift ***** of anything I've ever driven.

 

Looks good! I like the shifter too!

 

I agree the autos are a POS , had my out three time before I swapped ZF5 and PSD.

 

did the pictures link work for anyone else? i just clicked on it and got an error from facebook saying the page can't be displayed.

i don't have a spacebook account - could that be the issue? if so, i'll be getting my wife to log on for me...

 

Glad to hear you got it done! I like that shifter too...and the purdy and clean ZF!

 

Doesnt work for me either and I'm logged in right now.

 

ok, im not sure what the problem was but I think this link will work now even if you don't have facebook.
https://www.facebook.com/media/set/?...1&l=af98abf5a0

and thanks for the comments.

 

nevermind that one isnt working either. I'll update this thread if I ever figure it out.

"https://www.facebook.com/media/set/?set=a.10100683091650846.1073741827.19507541&type= 1&l=af98abf5a0"

Okay heres what you have to do, copy everything in quotes and then paste it in a new tab or whatever. I guess FTE doesnt allow you to hyperlink to fb. who knew?

 

That one works .

I like the cover photo.