There will be an update to this thread in a few days, I should be picking up the tranny by the end of the week. I just finished the D60 swap and have been enjoying driving it around the last few days....well back under the knife she goes.

 

Details and pictures.

 

So here is a little history lesson on the truck, this is how I got it




It was a huge piece of junk, it needed everything except the motor....somehow it grew on me

so I decided it needed all new sheet metal






and after the new body


I did a ATS turbo kit also but I can't find pics of that right now, I'll snap some tomorrow and add them in

Then out with the junk TTB44



and the D60 front in place



Since the last picture I have gotten it all buttoned up and have been driving it and it rides and handles sooo much better. I am sold on the solid axle swap. If the parts store would have ordered the right parts even once it would have only taken me about 16 hours to do. But it took me 2 weeks due to incorrect parts over and over.

The zf6 swap I imagine will take me a month at the pace I go.

 

Well one thing is for sure you sure changed the appearence of that ride.

 

I feel for you guys haveing to work with that rust,nothing worse than rust in your eyes.

 

Just got back from Chicago with all of these goodies!!....

01' superduty driveshafts and crossmember


01' superduty shifter and clutch...count those gears!!!!.1 2 3 4 5 6 & R


01' superduty starter....looks pretty close to the IDI starter


01' superduty flywheel


01' superduty clutch master cylinder


01' superduty NP-271f



01' superduty drum role please.....ZF-6!!




and to finish off the pictures my Dodge's bed filled with all of the above:





I can't believe how much beef this tranny has, it is sooo much bigger than the T19 that is in there now. I am sure that this install is going to take me quite a few weekends but I will make sure to document each step as I go and post as many pictures as possible. I might take the cab and bed off again to make it as easy as possible. I am anticipating that I will be cutting out some of the floor to make room for this beast....can't wait to get started.

 

Kaotikedge,
Could you please resize the pictures you're posting. Makes loading time pretty slow and the pictures are tough to view when you have to scroll across the whole thing.

Looks like a great project, though. Keep us posted on how it works out.

Jason

 

yes please keep us updated, i cant wait till you get that thing in there, i have thought about doing that swap before, right no im currenly putting a wastegated psd turbo on mine, but im going to take my time with it and make sure i dont screw anything up

 

I apologize if the pictures are taking too long to load on your pc....but maybe you ought to think of upgrading your pc or internet connection....these photos were taken with a cell phone and uploaded to Photobucket...they aren't exactly high res photos.

 

do u have a wife and can i find one like her my girl freind would have killed if i brought how all that stuff and if not ot muck how much did this cost

 

No, I don't have a wife....I have a few different girls that I "talk" to....but they all know better than to say anything about what I spend my ca$h on.

It wasn't that much Joe, with the amount of towing and traveling I do with the truck pulling my wheeler and trailer it will be worth it many times over.

 

It's not the resolution, but the physical size of the image. You shouldn't have to scroll across the page to look at the entire picture. My internet connection is just fine (T3??, I believe) and it loads pages pretty quickly. But not everyone has access to high speed internet and are stuck with dial up. Takes a bit of time to load 13 normal sized pictures in a single post. If they are way oversize, it can take all day.

If you resize your pictures to about 800x1000 pixels (like the before pictures in your previous post), it would make viewing your posts much nicer.

Jason

 

If there was a way for me to edit them now I would, the edit link on my post isn't up any longer.

 

There is much debate about whether the IDI is comfortable spinning dual counter shafts and a pump.

Some say it eats just enough power to drop the IDI rpm's. Thus making You downshift earlier. I dunno?

I found a little info on Jaybee's swap.

Ok, I am still getting occasional requests for info on how to do this swap, so I'll make a post with all the info I can remember on how to do it. It's been almost 2 years since I did it, so please excuse anything I forget to mention.

I now have about 20,000 miles on the truck with the conversion, and could not be happier. My only complaint in that time was with the ceramic puck style clutch disk I used. I have since replaced it with a conventional LUK disk and love it! There will be more on this to follow.

First of all, you have to remove the approximately 1" thick adapter plate the IDI's use in order to get the clutch and flywheel spacing correct. In other words, the bellhousing on the ZF6 is deeper and the input shaft is shorter, so the spacer has to go. The 7.3 powerstrokes have a different bellhousing bolt pattern cast into the block compared to the IDI. The good news is the 2 dowel pins, and 4 lower bolts do match up. The upper 2 bolts are the only difference. I made a stepped adapter to go from the upper 2 bolts on the IDI block to the upper 2 bolts on the ZF6. It was 2 pieces of 1/2" x 2" flat steel bar overlapped and welded together, making sure both bars were parallel after welding. The lower bar bolts to the upper holes in the block, and the upper bar sits behind it and has the upper 2 holes tapped for the tranny bolts. That makes the front face of the upper part of the adapter flush with the rest of the bellhousing in the block. I bought the stock tranny dust plate for a '99 and had to cut a little clearance into it for the adapter.

The next big hurdle is the clutch. The ZF6 has a 1.375" input shaft, and the smallest disk you can find with that spline is going to be 13" diameter. A 13" disk will not fit under any pressure plate that fits an IDI flywheel. My first way around this was to use a custom made 12.25" disk with the 1.375" spline and 4 ceramic pucks per side. This disk turned out to be miserable! The more you tried to slip it, the harder it grabbed sending the truck into convulsions. Backing up to a trailer was virtually impossible. So, I recently went a different route.

I had already used a LUK solid flywheel, so I pulled it back out and redrilled it for a LUK 13" PSD pressure plate. I now have the LUK pressure plate and disk for a '99 PSD and it works great. It reduced the pedal effort, virtually eliminated the gear rollover noise, and is very smooth. This is definitely the way to go. Oh, and you can't use a LUK flywheel for a PSD because they have a different bolt pattern on the crankshaft.

The clutch hydraulics weren't too bad, but not a simple bolt together deal, either. I used the correct master cylinder for my year truck. I used a slave cylinder for a '99 ZF6. The fork, pivot, and throwout bearing were all for a ZF6. The only real problem was trying to come up with a clutch hose that would work. I ended up making adapters that fit into the clutch and slave with a -3 AN on the other end. I then made a stainless steel braided hose to connect them. Bleeding was the typical pain, but it has worked great ever since.

The shifter ended up in exactly the same spot as a ZF5, so the tranny tunnel cover for a manual and boot all bolted up fine. I made my own cross member for the back of the tranny by heavily modifying the one that was in my truck with the E4OD. You might be able to bolt in a cross member from a '99 ZF6 - I'm not sure - was too cheap to buy one.

Of course you'll have to visit a driveshaft shop and get yours modified or a new one made. I also went to a '99 E350 disc brake rear axle at the same time, and had an all new driveshaft built to fit.

The ZF6 does not have a speedo drive gear. This is where a '92 up truck has the advantage. I used a speedo from the '92 up truck and made it fit inside my cluster with some slight customization. The '92 up speedo is all electronic, and I was able to drive it from the sensor on the rear axle.

The 7.3 IDI starter bolts directly into the bellhousing of the ZF6 and works fine. The bellhousing lower cover for the '99 bolted right up.

Oh, I did have to bend the floor of the truck up just a little bit for clearance, but it's under the seat and totally unnoticable.

I think that about covers it... If I remember anything else I'll reply to this post. If anyone wants a flywheel redrilled I could probably take care of that part of the conversion for them.

Jason


Man those heooge azzed pics really suxor on dial up

 

Sure would be nice if that swap text was posted in a thread that can be read!

Thanks

-Enjoy
fh : )_~