Ok i just got an offer from a friend of mine. He said he's tired of having a manual tranny and wants an automatic. Since ive always wanted a 5spd instead of the e4od i told him we should swap. He took me seriously..What do i do?

He has a 96 f-350 crew cab powerstroke dually 5spd
I have a 92 f-350 crew cab 7.3idi dually E4OD

What all is entailed in this swap. I may have it figured out and correct me if im wrong.

Swap driveshafts(different lengths)
swap Mounts?
swap trannys
Swap flex plate for flywheel and clutch assembly
Will i need to have crankshaft drilled for pilot bushing?
swap pedal assemblys(any brackets under dash that may need for this)
Swap steering colomns along with any linkages(does the 96 have an air bag?)
Wiring?Are the harnesses the same or are they different from a manual to an auto?Or are they different because of the years of them.

will his radiator accept tranny lines or just use external coolers anyways(I have two externals mounted on mine(PO didnt want his trans to overheat i guess))
Will i have to cut a hole in my floor for shifter Or is there a plate that just needs unscrewed.
Will a bench seat still work with the 5spd shifter?
An yways thanks for any help(if you can)(or want to)

 

I can't answer any of your questions for sure but this may help. I would have to look at my 94 tom. to be sure but as far as the older 80's cabs the floor board has a seperate piece of metal on the hump where the stick would be that you two may be able to swap out. The same for the pedal assemblies. Look at your firewall just above and to the right of the steering column and see if you see a upside down "teardrop" with two small dimples one at the top and one at the bottom. If you do, that is where the clutch master cylinder will go. The dimples are the bolt holes for the master cyl.

I am not for sure on these years. I can tell you anything you need to know on the early eighties. I have down this swap. I have a stripped down 86 cab out in the shop right now.

No matter what, this is alot of work but nothing is complicated.

 

I'm sorry, but taken out of context, you have to admit, that is funny lol.

The wiring harness is VERY different between the two trucks, and your friend will need either a standalone controller, or to completely re-do the stock harness over to one that can accept an auto tranny. And even then, there are internal electronic differences from 1992-1996 in the E4OD (you would have to swap the solenoid body with a newer one). It might be possible to take the computer and harness out of your truck, since it is basically a standalone setup (the IDI diesels are all mechanical, unlike the powerstroke).

If the trucks both have the same wheelbase, then swapping driveshafts should work.

To get the shifter from his truck to yours, you may just be able to swap the floor panel that the shifter is mounted on. And yes, the manual trannies were offered with bench seats in the same truck.

To fit the tranny, you could probably swap the crossmembers, but you may still have to drill new holes in the frame.

The rad for a manual tranny will not have a cooler for an auto, so a seperate one will have to be fitted, but its usually better to do that anyway.

As for swapping the pedal assemblies, steering column and related wiring, my guess is that mechanically, they could work, but chances are the wiring would again be different.

I'm not sure about the flywheel/flexplate swap, so some one else will have to chime in on that one.

Overall, it will definately be an exersise in patience.

 

<TABLE cellSpacing=0 cellPadding=4 width="100%" border=0><TBODY><TR><TD class=alt2 style="BORDER-RIGHT: 1px inset; BORDER-TOP: 1px inset; BORDER-LEFT: 1px inset; BORDER-BOTTOM: 1px inset">He took me seriously..What do i do? </TD></TR></TBODY></TABLE> I'm sorry, but taken out of context, you have to admit, that is funny lol.


Yeah it got me laughing
anyways i think youre right about the differences in wiring.
Was thinking about this and it just dawned on me about the fipl. Dont these trucks use different ip's. Wouldnt that mean that the fipl wouldnt just swap over . Thanks for the help, Probably wont happen but he was serious so it got me thinking.

 

The powerstroke is throttle by wire (no IP either), so your best bet would probably be to mount the FIPL sensor on the accellerator pedal somehow.

 

I just changed my E40D to a ZF5 in my F350 crewcab. I had to get a pedal assy. from same year. I went with a SMF setup. The ZF5 is 5 inches shorter and the trans mount had to be changed. The frame changes width at the new point so the old crossmember did not fit, went to boneyard. I got front driveshaft with trans and transfercase. I now am looking for the middle driveshaft,with carrier bearing, that is 5 inches longer. The trans plate in cab is changable but I think there might be differences between 92-96 cabs. Hope this helps

 

Remember on a Power Stroke everything (tach, speedo, throttle, brakes, engine sensors) goes to the computer, then the computer tells everything (injectors, tranny, speedo, tach) what to do.

I don't think he will be able to use your trans controller, there is no FILP on a Stroke.
The tach signal should come from the CPS on the Stroke.
The computer is probably different for an auto or manual on a Stroke, but that is just a guess.
I would also guess the wiring is there, but blocked off since he has a manual tranny.

Just a guess, but I bet you buy less parts than he does before both trucks are running.

 

it isnt a good idea , the 96 would have to have a new pcm (powertrain control module) to work with an automatic , and if i remember correctly the steering columns are different also the 92 should be the old style and the 96 is modular again if memory serves , part of the wiring should be on the 96 but a critical section will not be present and the electrical connector on the transmission solenoid body is different also 89-94 was the early style 95-97 was the second style with 98 and up using a modulated torque converter clutch , an air only trans cooler isnt a good idea ford found out the hard way on the 99 and early 2000 models it needs the coolant to remove the greatest amount of heat from the trans fluid the only way i would attempt a swap would be to have a 95-97 f series to swap an automatic out of into it, by using the two trucks you have will get expensive buying the parts needed