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1987 - 1996 F150 & Larger F-Series Trucks 1987 - 1996 Ford F-150, F-250, F-350 and larger pickups - including the 1997 heavy-duty F250/F350+ trucks

T-case Floor Cutout

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Old May 8, 2023 | 10:04 PM
  #16  
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bulletpruf
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Different transmission. I'm using the ZF-5. Bronco got the M50D.
 
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Old May 9, 2023 | 04:50 AM
  #17  
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Originally Posted by bulletpruf
Different transmission. I'm using the ZF-5. Bronco got the M50D.
I just did a M5OD to ZF5 swap in my ‘89. The shifter is in the same location but none of this matters if you aren’t using the transfer case shifter for an ‘87. You still haven’t answer that question.
 
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Old May 9, 2023 | 06:50 AM
  #18  
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I cut a hole in my '87 cab for the shifter location seen in post 10. I had two trucks I grabbed a bunch of measurements from, but didnt end up using them in the end. I installed the engine/trans/Tcase and got under the truck with the shifter assembly. I believe I mounted everything except the shift rod itself and eyeballed where the "axis" was. Drilled a hole from underneath as a starting point and went back up into the cab to open up a square like the one seen in post 10. I found that it doesn't need to be that large in size. I opened up a square using a body saw, then test fit the shift rod. I shifted the tcase into all positions and trimmed the floor as necessary.
 
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Old May 9, 2023 | 07:53 AM
  #19  
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Originally Posted by My4Fordtrucks
I just did a M5OD to ZF5 swap in my ‘89. The shifter is in the same location but none of this matters if you aren’t using the transfer case shifter for an ‘87. You still haven’t answer that question.
This is the shifter that I have - https://www.ebay.com/itm/37468119214...Bk9SR47ikomAYg
 
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Old May 9, 2023 | 09:27 AM
  #20  
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That is the shifter I have in my ‘89. The hole is on the side of the trans tunnel shown in your picture from post #10.
 
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Old May 9, 2023 | 09:26 PM
  #21  
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bulletpruf
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Got it done today.

Started by drilling a hole from underneath to mark the center of the hole that needed to be cut. Cut a smallish hole with a cutoff wheel - maybe 2" x 2"? Then got the shifter mounted and figured out where it needed to be enlarged. Then a few more cuts with the death wheel (hole is now 3" x 3"), followed by a quick wire wheel, flap disk, and some paint. I have a shifter boot on the way; hope to install this weekend.


Transfer case rebuild kit arrived today. Hope to finish the rebuild Friday (took the day off work) and get it installed Saturday. Then I can start working on driveshafts.







 
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