Well I work in a Tranny shop 97 POWERSTROKE and all i have to say is money money money money! My boss even told me that you dont want to convert plus he also tells me that the E40D is better beefed up than any stick could be. Just my .02

 

i believe you'd have to have the driveshafts. transfer idk

 

A buddy of mine did a auto to stick conversion on a 99 f350. The TRANNY HUMP IS DIFFERENT ON THE SUPER DUTY'S. I have his auto tranny hump in the back of my truck. The manual is taller. He was able to reuse his original driveshafts but he had to change something(i believe input shaft) on his tranny case. He has bout $3500 in the swap. Again this applies only to 99+

 

Below is a copy and paste of all my previous post in order on the swap I did back in July. Sorry for the long length but I did not go though and delete anything:

I have been reading and learning on this site for years, thanks to everyone here! I don't get an opportunity or reason to post much, but I thought some folks may be interested in my latest undertaking.

I have a 1996 F350 Crew cab Long Bed 4X4 Auto with the Power stroke Diesel; I can not say enough good things about this truck and how it has treated me over the last 215,000 miles. EXCEPT for that cursed auto tranny!!

I have been through 4 of them the last one being heavily modified (Long list of mods I can go into later if anyone cares) and they just don't seem to last.

So I told myself if this one ever goes out I am going to put in a freaking manual tranny and be done with it. So here I go!

I went and got the following:
A 1995 Power stroke Crew cab Long bed Dully 2WD 5spd parts truck (I will have a LOT of left over parts if anyone is looking for stuff)

A South bend Con O clutch and flywheel kit

A rebuild kit for the ZF including bearings syncros and seals

A new 4X4 main shaft

A new 4X4 tail housing

Anyway I will keep this post updated as I go, and if anyone can lend any advice or pit falls I sure would like the feed back.
P.S. My spelling sucks... I know that already
Thank you for all the replies, I don't have that much $ into this swap:
A 1995 Power stroke Crew cab Long bed Dully 2WD 5spd parts truck $450
A South bend Con O clutch and flywheel kit $650
A rebuild kit for the ZF including bearings syncros and seals $250
A new 4X4 main shaft $120
A new 4X4 tail housing $130
Total = $1600

I don't think you can touch a BTS tranny and converter for lass than $5000

I tow a 12500lb trailer almost every weekend though the Texas summer heat and hill country. Most folks who tow big weight on a regular basis seem to agree that a manual is the ticket.

Now had I got a BTS tranny and converter back when my first tranny went out I would probably be even by now but the was almost 9 years ago now.
BTW this truck is also my daily driver; I can not afford to have it down for tranny repairs so to me a great warrantee to have the auto taken out and shipped some place does not give me a lot of comfort.

Nothing against BTS, but I don’t drag race or sled pull or mud bog this truck. I don't see why I would be concerned about how fast the power gets to the ground, so long as it gets there.
For those folks interested in doing this them self’s, it appears to be easy enough for now. Although I am not too far into it, I have removed the pedal rack, clutch master, steering column parts, instrument panel and shifter from the parts truck.

As far as the in cab wiring harness they appear to be the same and I don't see too many problems yet. There are wiring provision in the harness to go auto or manual form the factory. This makes sense to me but I was not too sure until I got them apart.

Now this weekend I will go after the heavy/dirty work under the truck. I will keep the updates coming.
Sorry for the delay, the wife wanted to go boating so half of last weekend and this weekend are a going to be lost on this project. I did get a chance to strip all usable parts off of my parts truck before the wife had it hauled off to the junk yard due to the folks next door making comments.

I have taken apart the 2wd manual ZF all the way and removed the main shaft and reassembled with all new bearings and syncros and seals and the 4wd main shaft and tail housing. I was really impressed with the condition of the gears, they look new in side. So the tranny is all done and ready to go in, and rebuilding it was not that hard. The worst part was getting all the old bearings off the shafts (high-speed is your friend).

So with a blessing form the wife I may get to start the install next weekend I hope.
OK it’s all done! It took me 3 days to do it. Needless to say I am very happy with the results so far. I changed everything over so you can't tell it’s a conversion:
Steering column, floor plate and ever took the dash apart a put in the blanking plate where the auto gear indicator was.

The swap was pretty easy except for two things:
1. The E4OD 4X4 mount does not directly work for this combination and neither does the 5 speed 2WD one. I had to use parts from both to make up my 5 speed 4X4 mount. Plus 2 new holes in the frame on each side, but that was the worst part of the job.

2. The tranny/transfer case wiring harness does not plug and play between a 1995 and 1996. The connector do mate up but the pin out is different so I had to depin the harness and move the 4X4 indicator light wires and the clutch interlock jumper wires around to mach my truck.

All else was plug and play. The pedal rack and clutch cylinder went right in and the cab wire harness has a jumper plug you remove and then plug right into the clutch interlock switch. The steering column was easy no problems there, just a connector to tie back to the cab harness that was used to operate the auto gear shift lever solenoid. The floor pans swapped easy just rolled back the carpet and swapped them out and the used to hole in the 5 speed pan to cut the hole in the carpet for the shifter. Had to get the front drive shaft shortened and the rear lengthened (actually I got me parts truck 2WD rear shorted instead because shorting is way cheaper then extending). Oh and I did have shorten the sifter rod for the 4X4 transfer case because the one for the auto was too long. The new solid flywheel and clutch from south bend went in no problem and the tranny and transfer case bolted right up and went right in.

The truck is actually getting better fuel mileage around town and on the highway which is weird since the RPMs are a little higher ant the same speed and my old auto. I went from 15-16mpg at 70mph to 17-18 at 70mph. who knows why???

Other notes are the 1st gear is totally not needed while empty I just start in 2nd. But when I am pulling by boat (12000lb) I sure do like it. It tows a lot better than before, really not even close, it’s like a different truck. I will admit on the drive to and from work the is a lot of shifting going on.

I have about 800miles on the swap and so far all is well. Sorry for the long post but if there are questions on something I forgot please fire away.

 

Please note that was from july so now I have over 4000 miles on it and towing every weekend, with no problems what so ever.

 

You should just buy mine instead for 7500.00