okay so yesterday i bought everything to swap my 97 to a manual. i read the tag on the trans wrong and got a ZF5 S5-42. i would rather the higher gearing for highway driving and all but i was wondering if it will be able to hold up with the motor. its out of a late 94 powerstroke. i have a ts tune 6637 and exhaust. i think with a decent clutch it should be fine but i dont know! someone please help!

 

That trans will be just fine. Unless you're going for ultra high HP levels, you'll be fine. The only real difference as far as drivability is concerned is that the S47 has a lower (even more useless) 1st gear. I kind of wish I had the 1st gear ratio from the S42 in mine, to be honest. It will work just fine, the improvements to the S47 are pretty minor in my opinion.

 

great thats the answer i was hoping for! also do you know what pcm will work? i have an SOD4 that i got out of that truck but from what i read you need the ALF6. and will my transfer case from the E4OD work or no?

 

Transfer case will work just fine. Just swap it over. Did you get new driveshafts with your kit, though - you'll def need those.

As for PCM, any PCM from any manual trans obs powerstroke will work. Not sure of codes, but mine came from a dump truck and worked fine. Though if you have a chip, I believe you can just get it reburned for a manual trans and use your current PCM still.

 

i got a front driveshaft with it im just going to get my rear one redone. so what youre saying is if i get my chip reburned i can use my auto pcm???? that would be great! and the transfer case is a direct bolt on?

 

I'm no chip expert - don't have one YET - but as I understand it, yes, a chip reburn to manual should enable you to use your auto PCM. Hopefully someone else will confirm.

And yes, the tcase will just swap right over from your e4od to the zf5. Actually, I did the exact same a swap - 97 4x4 e4od to 4x4 zf5-42. Just unbolt and yank off the auto, slide onto and bolt onto the zf. You'll have to swap over the 4x4 selector plate and linkage as well. And shorten the connecting bar. I forget the exact amount to shorten by, but I'll look it up and post this week. If you need it ASAP, PM Rebilld. He's the man with this zf swap stuff!

 

okay buddy! thank you! how does the 42 do with daily driving?

 

Awesome! I love using all 4 limbs again!

I find that first, while quite low, is useful - unlike 1st in the 2wd 97 gasser that I have, which is totally useless unless you need to pull a house straight up a wall!

I use first in the 7.3 whenever starting from a dead stop with either a cold engine and/when pointing up a hill - and obviously when towing. Once she's warm, pointing downhill or level or moving at all, starting in 2nd is best. Oh and I have 3.55 gears...

 

great! i have 4:10's think it will still be okay? not going to limit my top end maxing at 65 or anything

 

Your auto PCM will work just fine but you will get the romps on start up. Have your chip burned to the newest and greatest manual PCM code, which I think is ALF4 or 6. The chip will override everything in the PCM and since your swapping in a 5-speed you will be fine to use what ever code PCM, auto or manual.

Clear as mud right...

Diesel Rod

 

Your RPMs will be noticeably higher than with the auto but no, you won't be maxed at 65.
^^^This^^^

 

I don't get all the hate on the 5.08 1st gear? I use mine EVERY time I take off and wish I had a lower 1st when taking off with the trailer.

I am seriously considering getting a 460 trans and putting the guts into my spare s42 housing

 

I like my 1st gear just fine but would be ok with it being a hair lower or higher too.

How is the 4.66 R? That's my biggest problem with the S5-42. The 3.79 R is aweful.

 

I did the swap on mine. I put in a s42 from a 93. My truck has 4.10 gears. I absolutely loove it. I almost always use first gear to start out. Oh, I already had a ts chip for the auto installed, still running it, with the auto pcm. I never got a romp at start unless the temp is down around 20 degrees.

 

There are many time I put the tease in 4LOW to jockey the trailer around because Reverse is NOt low enough.

But I use my truck, which it doesn't seem like a lot of guys here do other than just to drive it