i have a 91 f150 4x4 with the e4od, i was wondering how hard it would be to swap in a zf transmission?

i have the 1356 xfer case would i need a longer drive shaft?

i know im going to need the pedal assembly
master and slave cylinder with lines
clutch, fork bell housing etc.. im just wondering what else i would need and what i would have to modify to make it work


only reason is a buddy of mine has a few zfs out of a couple 2wd f150s laying around and he told me i could have them. he just doesnt have the other parts

 

The search function will give you tons of pages from people who have done this. Here's one that went into pretty good detail about what parts would be needed:

https://www.ford-trucks.com/forums/5...onversion.html

And yes, your rear driveshaft would most likely need to be lengthened and your front would have to be shortened; don't forget about the front shaft ;-)

So how many ZFs does your buddy have and where is he located? I was planning on doing this swap sooner or later too.

-Chris

 

well he's located here in missouri about 15 miles away from drexel, and he has about 20 of them and he said i could have 5 or 6 of them, because he didnt know which were good or bad.

will a 2wd work as a 4wd tranny? whats the spline count on the xfer case then?

 

No, the 2wd and 4wd transmissions are different. You would have to replace the output shaft as well as the tailshaft housing and re-set the bearing preload on the mainshaft and countershaft. Unless you had the tailshaft housing and output shaft to swap onto the 2wd case I would think the cost would be prohibitive. IIRC the spline count is 31 on the output shaft/transfer case. Remember you need to get a ZF with the 300/302/351w bellhousing bolt pattern and not the 460 or diesel pattern.

You would think out of all those ZFs laying around he would have some 4wds in there.

 

Good to know gustang. You seem to be quite the tranny guru. I read the really long thread about nighthawk trying to diagnose his problems with the AOD-ZF swap; you're very helpful in this field.

-Chris

 

Thanks for the pat on the back. I have a degree from at the Skool of Hard Knocks in that area. I hope that maybe what I post will help someone avoid some trouble or frustration. As far as a guru, there are some real ones over at the transmissions forum that amaze me with what they know.

 

Some people know motors inside and out, I just picked up trannys better

If'n yer buddy don't have what you need, start lookin' fer a...

'88-'96 F-2/350 4x4 with the 300 or 351w for it's ZF S5-42.
'96-'97 F-250HD/350 with the 351w for it's ZF S5-47.

Just a 50lb torque handling rating difference.

You'll need a pedal assembly from a '84-'91 Truck. The '92+ changed a bit.

You can keep yer automatic computer, but the CE light can come on for all the E4OD's trouble codes. Won't affect the motor though.

What motor you runnin? You'll need an appropriate flywheel.

Adrianspeeder

 

I've seen other guys on here say that the transmission codes won't trigger the CE light but they will come up on the scanner when you scan for other codes. I could live with it threw 6 or 7 codes when I pull the codes but that would **** me off if the CE light was on all the time.

-Chris

 

That's what they make black electrical tape for

 

Haha, well I guess that's one technique. But I also would like to know when my check engine light is actually telling me 'CHECK THE ENGINE CHRIS!!' vs. just crying wolf, ya' know?

Also I like to take pride in keeping my truck in a condition that makes it seem like a new truck even though its 12 years old, so that people with an untrained eye (ie, college girls in my college town ) might think that it is a new truck, as they have many times before. Black tape covering lights on my cluster might give the appearance of a junky old truck, no offense to all those black tapers out there

-Chris

 

Hey!!! I cut the tape with a scissors so it looks nice to the untrained eye. Seriously, I did a carb conversion so the light is on all the time and it does get annoying. Here in the rust belt most 12 year old trucks look 12 years old so the college girls know it's not a new truck even before they see the black tape. And most of them wouldn't be caught dead climbing into a truck with an old guy like me. "Ewwwww, is that your dad?"

 

Hahaha, well at least you're honest. So getting back on topic, is there anyway to do a tranny swap and NOT have a check engine light, short of changing out the PCM (I assume that would do the trick)?

-Chris

 

Maybe if you trick the PCM into thinking there is a transmission by using resistors or something. Where's Eric (epncsu2006) when you need him?

You may be able to find a manual trans computer locally at www.car-part.com

 

Naaa, nothin' to be done to replicate the MLPS and TCC to trick the computer.

You gotta find a computer from the same engine with a stick/C6/AOD.

Adrianspeeder

 

AOD?? That's an automatic transmission. Perhaps you mean M5OD?