OK, I realize this is a little bit of a crazy question, but has anyone ever swapped out an auto trans in one of these trucks in favor of a Zf5? I did a quick search and didn't come up with anything...

I know it will be a step backward in towing capacity, but here's the story. I have a 96 extended cab F250 right now and have all the parts gathered for an E4OD (auto) to ZF5 (manual) swap - mainly for personal preference reasons of manual trans vehicles being more awesome that auto trans ones - personal preference, I know... anyway, the wife recently decreed that we need a crew cab for the growing family. I've been in the market for a few months now and have been looking for a 7.3 4x4 crew cab with a manual trans and reasonable miles (OBS or SD, though new would be preferred, obviously).

I haven't been finding much, but recently found a pretty good deal on a 99 4x4 Dually Crew Cab. problem is that is automatic, so i'd be looking to swap out the trans for manual sooner rather than later. I know the ZF5 and flywheel that I have sitting in my barn will bolt to the engine just fine, but I don't know about the transfer case on the SD trucks - I think I remember reading the output shaft of a ZF6 is larger than a ZF5? if so, i'd need to get an older transfer case to do the job, right?

then, i'd need new driveshafts, pedals and a new or modified tranny support member. ...and i'd have to get the PCM reflashed. anything else i'm missing? new cab floor plate (or cut a hole)...

any input/experience is much appreciated.

Thanks!

 

i have seen a zf6 put in but dont know if the zf5 will work.

 

i wanna say, E99, depending on build date, did come with zf5.

post #25 https://www.ford-trucks.com/forums/1...ion-oil-2.html

 

thanks for the thread - I read through and it seems like either E99's did come with the zf5 as the base transmission or at least someone has done a swap to one - which is good enough for me. finding a trans crossmember would be darn near impossible, but I'm sure I could modify the auto crossmember to make it work. worst case i'd be putting an old 4407 or 1356 tcase on the back of the zf5 and having custom driveshafts made but that's no big deal...

ok, thanks for the info gents. now to decide whether to pull the trigger or not...