Notices
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

4x4 Conversion Floor Cutout

Thread Tools
 
Search this Thread
 
Old Jul 2, 2022 | 11:42 PM
  #1  
SVandal's Avatar
SVandal
Thread Starter
|
Tuned
5 Year Member
Liked
Loved
Community Favorite
Joined: Mar 2017
Posts: 417
Likes: 37
4x4 Conversion Floor Cutout

In process of finishing my manual swap and 4x4 conversion. ZF5 is almost finished and ready to go back in. Only thing I need to do to the cab still is to cutout the floor for the transfer case shifter. I'm looking for a good picture of the stock cutout and location so I can get close without going too big. I'd like to get it all cut out and drilled before putting the transmission under there.
 
Reply
Old Jul 3, 2022 | 12:24 AM
  #2  
AuroraGirl's Avatar
AuroraGirl
Lead Driver
Shutterbug
Community Builder
Liked
Loved
Joined: Jun 2021
Posts: 5,219
Likes: 804
Originally Posted by SVandal
In process of finishing my manual swap and 4x4 conversion. ZF5 is almost finished and ready to go back in. Only thing I need to do to the cab still is to cutout the floor for the transfer case shifter. I'm looking for a good picture of the stock cutout and location so I can get close without going too big. I'd like to get it all cut out and drilled before putting the transmission under there.
engine...?
Id assume you have a t case stick as well? or is it electric?
 
Reply
Old Jul 3, 2022 | 12:32 AM
  #3  
SVandal's Avatar
SVandal
Thread Starter
|
Tuned
5 Year Member
Liked
Loved
Community Favorite
Joined: Mar 2017
Posts: 417
Likes: 37
Originally Posted by AuroraGirl
engine...?
Id assume you have a t case stick as well? or is it electric?
tcase is manual as well. I have a spare electrical shifting Tcase, but prefer the reliability of the manual.
 
Reply
Old Jul 3, 2022 | 12:44 AM
  #4  
AuroraGirl's Avatar
AuroraGirl
Lead Driver
Shutterbug
Community Builder
Liked
Loved
Joined: Jun 2021
Posts: 5,219
Likes: 804
Originally Posted by SVandal
tcase is manual as well. I have a spare electrical shifting Tcase, but prefer the reliability of the manual.
so you need to know where the cutout for that as well would be? I ask because im assuming it goes up into the same area of the center area
 
Reply
Old Jul 3, 2022 | 01:12 AM
  #5  
Toork's Avatar
Toork
Tuned
Joined: Jan 2021
Posts: 303
Likes: 66
don’t mind the color… 😅 is a water proofing agent. This is in my 351 Auto, so cut might be different. 🤷🏽‍♂️



My Build: https://www.ford-trucks.com/forums/1...#&gid=1&pid=18
 
Reply
Old Jul 3, 2022 | 07:04 AM
  #6  
SVandal's Avatar
SVandal
Thread Starter
|
Tuned
5 Year Member
Liked
Loved
Community Favorite
Joined: Mar 2017
Posts: 417
Likes: 37
Originally Posted by Toork
don’t mind the color… 😅 is a water proofing agent. This is in my 351 Auto, so cut might be different. 🤷🏽‍♂️

My Build: https://www.ford-trucks.com/forums/1...#&gid=1&pid=18
thanks! No worries on the color. Besides, carpet or vinyl will be covering it eventually. I’ll check my floor pan for the cut or dent outlines. I imagine they are the same location. I don’t think ford would have wanted to keep track of 10 different floor cutouts. But maybe they did.

your build looks great. It looks like you have done a lot of work on your interior that I’ll need to do in the next year or so.
 
Reply
Old Jul 3, 2022 | 08:17 AM
  #7  
Robfinger's Avatar
Robfinger
More Turbo
Joined: Dec 2021
Posts: 554
Likes: 186
A lot of trucks already had that opening cut out, and blanked closed by a cover held in by several screws and a sticky foam gasket. Did your truck have the top over the ZF removable already if so then those usually have bolt-on t- case openings covers as well.

There do exist F150s (or was it Broncos) where the floor sheetmetal is a solid piece, no removal transmission tunnel cover - first time I saw one of those I had to examine the whole thing to verify that I'm indeed seeing what I'm seeing.
 
Reply
Old Jul 3, 2022 | 08:21 AM
  #8  
SVandal's Avatar
SVandal
Thread Starter
|
Tuned
5 Year Member
Liked
Loved
Community Favorite
Joined: Mar 2017
Posts: 417
Likes: 37
Originally Posted by Robfinger
A lot of trucks already had that opening cut out, and blanked closed by a cover held in by several screws and a sticky foam gasket. Did your truck have the top over the ZF removable already if so then those usually have bolt-on t- case openings covers as well.

There do exist F150s (or was it Broncos) where the floor sheetmetal is a solid piece, no removal transmission tunnel cover - first time I saw one of those I had to examine the whole thing to verify that I'm indeed seeing what I'm seeing.
mine is a solid sheet. I had to cutout the floor pan to install the tunnel cover.
 
Reply
FTE Stories

Ford Trucks for Ford Truck Enthusiasts

story-0

Top 10 Ford Truck Tragedies

 Joe Kucinski
story-1

AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make

 Brett Foote
story-2

Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!

 Michael S. Palmer
story-3

Ford's 2001 Explorer Sportsman Concept Looks For a New Home

 Verdad Gallardo
story-4

10 Best Ford Truck Engines We Miss the Most!

 Joe Kucinski
story-5

2026 Shelby F-150 Off-Road: Better Than a Raptor R?

 Brett Foote
story-6

2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!

 Michael S. Palmer
story-7

10 Most Surprising 2026 Ford Truck Features!

 Joe Kucinski
story-8

Top 10 Ford Trucks Coming to Mecum Indy 2026

 Brett Foote
story-9

5 Best / 5 Worst Ford Truck Wheels of All Time

 Joe Kucinski
Old Jul 3, 2022 | 06:27 PM
  #9  
Robfinger's Avatar
Robfinger
More Turbo
Joined: Dec 2021
Posts: 554
Likes: 186
F150? Or 250/350? Pure curiosity on my end at this point 😇
 
Reply
Old Jul 3, 2022 | 06:51 PM
  #10  
SVandal's Avatar
SVandal
Thread Starter
|
Tuned
5 Year Member
Liked
Loved
Community Favorite
Joined: Mar 2017
Posts: 417
Likes: 37
Originally Posted by Robfinger
F150? Or 250/350? Pure curiosity on my end at this point 😇
F-250. Same cab as an F-150. My 1996 and 1997 2wd F-250 cabs both had solid floor cabs.
 
Reply
Old Jul 3, 2022 | 07:51 PM
  #11  
AuroraGirl's Avatar
AuroraGirl
Lead Driver
Shutterbug
Community Builder
Liked
Loved
Joined: Jun 2021
Posts: 5,219
Likes: 804
Originally Posted by SVandal
F-250. Same cab as an F-150. My 1996 and 1997 2wd F-250 cabs both had solid floor cabs.
I could have swore my 96 f150 2wd had a cutout with just a blank sheet covered it with screws fastening it. however, the only pic I have on phone of the area is JUST the back half of my e4od so if it was, i didnt capture it. And i dont feel like crawling under it lol but Maybe its a E4OD thing who knows. or maybe i remember wrong
 
Reply
Old Jul 3, 2022 | 07:59 PM
  #12  
SVandal's Avatar
SVandal
Thread Starter
|
Tuned
5 Year Member
Liked
Loved
Community Favorite
Joined: Mar 2017
Posts: 417
Likes: 37
Originally Posted by AuroraGirl
I could have swore my 96 f150 2wd had a cutout with just a blank sheet covered it with screws fastening it. however, the only pic I have on phone of the area is JUST the back half of my e4od so if it was, i didnt capture it. And i dont feel like crawling under it lol but Maybe its a E4OD thing who knows. or maybe i remember wrong
May depend when each line ran out of the cutout bodies. I’m assuming that at some point a Ford worker figured out that leaving them solid saved $3.26 per truck.
 
Reply
Old Jul 3, 2022 | 08:51 PM
  #13  
JJF20's Avatar
JJF20
Hotshot
Joined: Nov 2017
Posts: 17,456
Likes: 2,767
From: Northern Ontario
I have my cab (1996 regular cab) open and the floor bare right now if you need anymore pics or measurements. Just send me a pm if you need them.
 
Reply
Old Jul 4, 2022 | 08:34 AM
  #14  
JJF20's Avatar
JJF20
Hotshot
Joined: Nov 2017
Posts: 17,456
Likes: 2,767
From: Northern Ontario
Here you go…. If you need another angle or something, let me know. Hard to show a good measurement with the curve at the bottom. If you have the plastic interior cover, it might help with that.











 
Reply
Old Jul 4, 2022 | 12:31 PM
  #15  
SVandal's Avatar
SVandal
Thread Starter
|
Tuned
5 Year Member
Liked
Loved
Community Favorite
Joined: Mar 2017
Posts: 417
Likes: 37
Originally Posted by JJF20
Here you go…. If you need another angle or something, let me know. Hard to show a good measurement with the curve at the bottom. If you have the plastic interior cover, it might help with that.

That’s great, thank you! I’m going to go measure and cut mine.
 
Reply



All times are GMT -5. The time now is 10:08 AM.

story-0
Top 10 Ford Truck Tragedies

Slideshow: Top 10 Ford truck tragedies.

By Joe Kucinski | 2026-05-18 19:34:33


VIEW MORE
story-1
AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make

And it might be even better than that.

By Brett Foote | 2026-05-18 19:26:42


VIEW MORE
story-2
Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!

Slideshow: Does lowering an F-150 Lobo RUIN the ride quality?

By Michael S. Palmer | 2026-05-18 19:20:37


VIEW MORE
story-3
Ford's 2001 Explorer Sportsman Concept Looks For a New Home

Slideshow: Ford's bizarre fishing-themed Explorer concept has resurfaced after spending decades largely forgotten.

By Verdad Gallardo | 2026-05-12 18:07:46


VIEW MORE
story-4
10 Best Ford Truck Engines We Miss the Most!

Slideshow: The 10 best Ford truck engines we miss the most.

By Joe Kucinski | 2026-05-12 13:09:47


VIEW MORE
story-5
2026 Shelby F-150 Off-Road: Better Than a Raptor R?

Slideshow: first look at the 810 hp 2026 Shelby F-150 Off-Road!

By Brett Foote | 2026-05-12 12:50:07


VIEW MORE
story-6
2027 Super Duty Carhartt Package First Look: 12 Things You NEED to Know!

Slideshow: Everything You Need to Know about the 2027 Super Duty Carhartt Package!

By Michael S. Palmer | 2026-05-07 17:51:06


VIEW MORE
story-7
10 Most Surprising 2026 Ford Truck Features!

Slideshow: 10 most surprising Ford truck options/features in 2026.

By Joe Kucinski | 2026-05-05 11:17:22


VIEW MORE
story-8
Top 10 Ford Trucks Coming to Mecum Indy 2026

Slideshow: Here are the top 10 Fords coming to Mecum Indy 2026.

By Brett Foote | 2026-05-04 13:49:49


VIEW MORE
story-9
5 Best / 5 Worst Ford Truck Wheels of All Time

Slideshow: The 5 best and 5 worst Ford truck wheels of all time

By Joe Kucinski | 2026-04-29 16:49:01


VIEW MORE