the e40d to a crap on me today and left me with a heavy tow bill. i dont wanna put another auto back in the truck and looking to do a swap over to a 6 speed or a 5 speed. ive heard of people doing this but im not sure what tranny there running and what all i will need. is it the zf-6 speed? what all will i need to do the swap and can it come out of a gasser? hoping someone has done this before and has a good parts list.

 

The 6 - speed is going to take a little more work because our trucks did not have them factory. I'm not aware of everything that needs to be done, but this tranny different from the 5 speed as it has a cooler and believe it is longer. You'll need to redo the cross member (something along those lines).

For the 5-speeds you'll want to go with a ZF-47 or 42. The 47's came from the 96-97 models and are supposed to be a little stouter (bearings, snyc's, torque). The gear ratio is also different.

Gasser tranny's like the M5od will not work on these diesels...

I'm sure someone else will chime in with more specific info.

 

I've seen a zf6 swap on PSN. I think you need to drop the tranny like an inch cuz its bigger. There is definitely more to it then a zf5.

 

Hey bud. I'm in the same boat as you. My auto slug is comin out soon as I get all of my parts. Here's the scoop. You can put in a ZF S5-42 or a ZF S5-47 if you want a 5 speed. They both came as options on our trucks with the 47 being on 96 and 97's only. You have to get one from a 7.3 for the bellhousing to fit but someone said that one from the 7.5L 460 gasser fits too but I don't know. The ZF 6 from a 98 - 02 7.3L will work too but there is some minor modding to do to your floor hump to accomodate for the size. It also has a cooler but I've heard several times to eliminate it to avoid a burnt tranny. Weird huh?
Now, parts list: Tranny, clutch set up(clutch plate, pressure plate, throw out bearing, pilot bearing/bushing, fork, etc.), clutch/brake pedals, master and slave cylinder and line between, tranny cross member, shifter and boot, tranny wiring harness and speed sensor, drive shaft(s) depending on 2 vs 4x4, manual PCM(although not mandatory especially if you have a chip that can be reburned), and a flywheel for a manual. If you don't want to have a goofy looking interior then you can get a steering column and the black plate to cover your PRND21 from a 5 speed as well.
From what I've seen and heard any of these things from a 94.5-97 powerstroke will work but some others may as well. I had some pedals form and earlier model that DO NOT fit so...
Here are some links that may help but you have to account for the differences in trucks. If parts seem weird then it's because they are slightly differernt from ours.
Auto to Manual Converstion - Powerstroke Nation
ZF6 Speed Swap into a 97 OBS - Powerstroke Nation
Auto to ZF5 Swap... Need info - Powerstroke Nation

Hope that helps

 

well if you were closer i'd sell you this zf5 i have from a 96 i parted out.new 1 pc flywheel and all.guess i need to post it for sell in classifieds

 

I think I would stick with the 5 speed. You may know this but the 6 speed gives you a granny gear and still one od gear.

 

redman84...
thanks, a lot of info i can use there. from what ive read on stores selling rebuilts its the same for a 460 as it is a 7.3. granted, ive only been looking online for three hrs but thats what ive seen so far. im trying to find a donor truck but no luck. searched craigslist at work all day and ive found one truck that may work but its a 460. so i figured i had better get my ducks in a row before i drive 6 hrs to look at it.

 

do you just have the tranny or do you have a pedal assembly and master cylinder as well? i may be interested. i have a 95 f350 as a back up truck so i can make a drive.

 

yeah, im just going to stick to the 5 speed. are all the pedals and the master cylinder the same on a f150? i can find them all over the place.


ok, i just found in dallas a guy that will sell me a zf5 + transfer case, master cylinder, slave, pedal assembly, and drive shafts for $2200. is that a good price? i also found a zf6 and transfer case for $1500 but the transfer case is electric. will it work?

 

i sent you a pm

 

I don't know about the F 150 stuff. I do know that the clutch pedal on the 250 has a freakin man spring in it and it would be hard for me to figure that the 150 would be as heavy.

As for the price of that setup, I feel like that is a little stiff but to find it all in one stop like that is probably worth it. I was collecting parts but am going to take them back to the yard since they offer a refund in 30 days as my lady found me a 95 donor twin of mine for well let's just say a great deal. It's a junker but the drive train and the rest of what I need is perfect. Don't forget about the cross member, starter, steering column, and PCM as well.

 

yeah, i thought it was a bit high myself. well i always wanted to do a dually conversion on it because they didnt make a 4x4 drw in these years and i was just going to buy the wheel adapters but i think i just hit the jackpot. i found a 96 f450 4x4 dump truck with a blown 7.3 and a 5 speed in it. im not gunna lie..... i was sporting wood when he told me what he wanted for it. $1500! i told him i will be up sat. to pick it up. now all i need is a bed, 6 inch lift and a set of american force 22 inch classic wheels and im set.

 

heck yea. Might even be able to rebuild the motor.
But b4 u do the dually conversion make sure that axle will work. Some cab chassis models have narrower frame rails. I think the axles are like 3 inches narrower then a dw bedded truck which puts the tires into the frame rail on the sw truck rails.

 

well if it is the same a 2x4 drw with a sterling then its wider if i recall. ive read about a lot of people doing the conversion but with a f350 axle. i guess ill find out lol. anyway, its worth the price just for the trans set up and the blown motor. i can get half my money back just on the injectors for cores.

 

That will definitely be super sweet if you pull it off. You may talk to Brown Falcon because he had a dually that he converted to single wheel. Different I know but he may have parts or advice. I also have an extra ZF 5 speed if you or anyone you know ends up needing it.