I have always hated my auto trans and kept telling myself that someday I'd convert to a 5 speed. Well someday has come. My torque converter is going out and the trans temps get higher than I'm comfortable with on anything more than a short drive. Also I'm finally in a position where I can down the truck for an extended period of time and have a decent place to perform the work. I have been researching what all I need to make this swap and I think I have a complete list of the major parts needed.

By the way my truck is a 97 f250 4x4 reg cab auto.

1. clutch/brake pedal assembly
2. master/slave unit
3. trans tunnel from a 5 spd or cut up my own
4. trans crossmember
5. shifter and boot
6. Single mass flywheel/clutch/pp
7. ZF 5 4x4 trans
8. and steering column cover without auto shifter hole would be nice

I know I will have to extend my rear drive shaft and shorten the front.
From what I have read it sounds like I will also need a pcm form a 5sp truck.(anybody know a good place to get one)? Is it possible to have my pcm reprogrammed to match that of a 5spd truck?

I already found the harness on my truck for the clutch safety switch and I am sure I can figure out how to make the reverse lights work with the ZF.

The only thing I haven't found an answer for is if my transfer case will bolt up to the ZF transmission. Im hoping it will but I realize I will probably have to modify the t case shift linkage due to the shorter length of the ZF trans.

Another question I have is will a trans crossmember from any 5spd 4x4 obs work (like even an f-150) or does it have to be from a 250/350 and does it matter if the donor truck was a psd or not?

I wanted to get a parts truck for this swap but it looks like that isn't going to happen now. I am attempting to get most of the parts from local salvage yards.

I've started parts hunting and will be tearing into my truck pretty shortly since I am not working right now and have lots of free time before college starts.

I appreciate any info. and advice on this swap. Thanks -Kellen

 

looks like you got it pretty well covered but you missed a couple things the bellhousing is different for a manual and an auto usually, And youll need to get or modify your belly pan to accept the shift tower. and you can get a pcm from a scrapyard or there on ebay alot you just neeed to know what codes will work for them. cuda jim has the year code applications if I remember right so you might want to PM him. Also the cross member should be them same from any OBS. Otherwise I think you got it. good luck

 

the bellhousings are the same between the two.

you will need a manual pcm.

im gathering parts to swap to an auto what part of the country are you in?

 

The PCM can also be reporgrammed for the manual as well. I would send it out to DP-Tuner or Power Hungry. They will get you set up nice. T-case will bolt up too. Just the change in the linkage like you said

 

Ok so the bellhousing is the same thats what i thought. What about the spacer plate between the engine and trans? Is that the same from e4od to zf5?

Barebackjake I sent you a pm. Lets talk!

Good to know that I can use my t-caseand that the pcm can be reprogrammed if I have a hard time coming accross one.

Thank you all for sharing your knowledge

 

you will need the spacer plate for the manual trans

 

I would LOVE to do this swap...I dont like having an auto

Good luck1!

 

I agree. I'd like to do this swap as well.

Are you willing to do a write-up listing all the parts you needed / used and where you obtained them? Posting pics of your progress would be a big help for alot of us considering this swap.

I'm subscribing to this thread so I can check on your progress. Good luck with this. It sounds like a great project.

 

Yeah I have been dreaming of doing this swap for the last four years (since the day I bought my truck). I will be glad to do a write up once its all completed. I will be taking lots of pictures during the conversion which I will include in the write up along with a list of all the parts needed.

 

I've got a ZF5 sitting at home in my '88 that I really think needs to go in my '95... only problem is that Home is in Oregon, and I"m stationed in North Carolina. Doh!

 

the one outta the 88 wont fit in the 95 differnt bell housings

 

Same bellhousing actually, all 7.3's had the same bellhousing. I just have to use pedal assembly and clutch/flywheel from a '95 truck.

 

Is it too soon to ask for a project update?

 

Not too soon to ask for an update. I just wish I had more progress to report. Ive been away from home for the last month so that didnt help. I hit all the pick-n-pulls in the bay area before I left and just the other day I found someone on craigslist parting out truck that I got some things from. Here is what I have collected so far:

1. Clutch and brake pedal assembly
2. Trans tunnel piece
3. Shifter mount, stick, and boot
4. Steering column cover
5. Trans crossmember
6. Trans wire harness

(On a side not I also scored an oem front bumper in awesome condition for 50 bucks and some 350 rear lift blocks)

The main thing I still need to find is the engine/trans spacer plate and of course the trans itself.

I was looking at rebuilts on ebay since i cant find anything locally but since I dont have a core to return and with shipping its going to be expensive.

I plan on ordering a valair clutch and flyheel kit as soon as I get the trans.

Does anybody know if a trans from a f-superduty will work? I think I read somewhere that even though they are two wheel drive that the rear section is the same as the 4x4 for reg pickups due the the driveline parking brake.

Ive got a lead on a trans from a 2 wheel drive f-supery duty for a good price if it will work. Im trying to research this right now.

Thats all so far. Havent started wrenching on anything yet. Just cleaning and painting parts, and new bushings for the pedal assembly.

 

go baby go!!! glad to hear your tearing into a project of this coolness. yes pictures please!! good luck