E40D swap to 5 speed manual
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Senior User
Joined: Aug 2008
Posts: 172
Likes: 2
E40D swap to 5 speed manual
Can someone give me a list of parts that I will need to swap a E40D too a 5 speed manual,I know I need these but what else ?
5 speed tranny
pilot bearing
clutch plate
flywheel
steering colum cover
foot pedal assembly
clutch plate bearing
5 speed tranny
pilot bearing
clutch plate
flywheel
steering colum cover
foot pedal assembly
clutch plate bearing
Hotshot
Joined: Jun 2007
Posts: 10,008
Likes: 7
From: Austin, TX
Let's see if I don't forget something while I type this.. lol
ZF5 trans
Flywheel
clutch
pressure plate
pilot bearing
throwout bearing
clutch release fork
slave cylinder
clutch master cylinder
clutch hydraulics line
shifter and shifter boot
either manual trans floor pan or cut the correct hole out of your auto floor pan
manual trans PCM and/or chip tuned for manual trans
manual trans wiring harness for reverse lights
manual trans crossmember
build driveshaft(s) to correct length or get driveshafts from correct wheelbase manual trans truck
steering column cover
P R N D 2 1 instrument cluster cover plate
clutch/brake pedal assembly
ZF5 trans
Flywheel
clutch
pressure plate
pilot bearing
throwout bearing
clutch release fork
slave cylinder
clutch master cylinder
clutch hydraulics line
shifter and shifter boot
either manual trans floor pan or cut the correct hole out of your auto floor pan
manual trans PCM and/or chip tuned for manual trans
manual trans wiring harness for reverse lights
manual trans crossmember
build driveshaft(s) to correct length or get driveshafts from correct wheelbase manual trans truck
steering column cover
P R N D 2 1 instrument cluster cover plate
clutch/brake pedal assembly
Lead Driver
Joined: Oct 2010
Posts: 5,132
Likes: 45
From: Columbus, Oh
Make sure you get the correct pedal assembly. Pre 93 won't work. Don't ask me how I know.
Travis, you don't have to run a manual PCM or even have a chip tuned for a manual. As long as the wiring is correct it will operate like its supposed to. I'm running both that are still autos.
Travis, you don't have to run a manual PCM or even have a chip tuned for a manual. As long as the wiring is correct it will operate like its supposed to. I'm running both that are still autos.
Cargo Master
Joined: Jul 2010
Posts: 3,014
Likes: 115
I'm pretty sure my pedals are out of a pre-'93 truck. They work fine. What about the pedals was not compatible?
To the OP, you can find all of the information about pretty much everything about the swap by reading through my pathetic struggle to get it done on my truck, lol. I'll get a link to that monster thread here in a second. Stand by...
Edit: Here you go. Click on the link to my thread here: Transmission Impossible
To the OP, you can find all of the information about pretty much everything about the swap by reading through my pathetic struggle to get it done on my truck, lol. I'll get a link to that monster thread here in a second. Stand by...
Edit: Here you go. Click on the link to my thread here: Transmission Impossible
Lead Driver
Joined: Oct 2010
Posts: 5,132
Likes: 45
From: Columbus, Oh
I'm pretty sure my pedals are out of a pre-'93 truck. They work fine. What about the pedals was not compatible?
To the OP, you can find all of the information about pretty much everything about the swap by reading through my pathetic struggle to get it done on my truck, lol. I'll get a link to that monster thread here in a second. Stand by...
Edit: Here you go. Click on the link to my thread here: Transmission Impossible
To the OP, you can find all of the information about pretty much everything about the swap by reading through my pathetic struggle to get it done on my truck, lol. I'll get a link to that monster thread here in a second. Stand by...
Edit: Here you go. Click on the link to my thread here: Transmission Impossible
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Hotshot
Joined: Jun 2007
Posts: 10,008
Likes: 7
From: Austin, TX
Make sure you get the correct pedal assembly. Pre 93 won't work. Don't ask me how I know.
Travis, you don't have to run a manual PCM or even have a chip tuned for a manual. As long as the wiring is correct it will operate like its supposed to. I'm running both that are still autos.
Travis, you don't have to run a manual PCM or even have a chip tuned for a manual. As long as the wiring is correct it will operate like its supposed to. I'm running both that are still autos.
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Lead Driver
Joined: Oct 2010
Posts: 5,132
Likes: 45
From: Columbus, Oh
The only time it romps is if I start and immediately let out clutch and add fuel. Only then and it's not often at all. Not sure I follow on the second question. I can let out the clutch with no throttle and it'll take off.
Cargo Master
Joined: Jul 2010
Posts: 3,014
Likes: 115
Hmm... My pedals may be out of a newer truck, then. There's really no way for me to know for sure without asking Ian (plgebbia), if he remembers.
Hotshot
Joined: Jan 2012
Posts: 11,132
Likes: 3
From: Southern West Virginia
Make sure you get the correct pedal assembly. Pre 93 won't work. Don't ask me how I know.
Travis, you don't have to run a manual PCM or even have a chip tuned for a manual. As long as the wiring is correct it will operate like its supposed to. I'm running both that are still autos.
Travis, you don't have to run a manual PCM or even have a chip tuned for a manual. As long as the wiring is correct it will operate like its supposed to. I'm running both that are still autos.
Lead Driver
Joined: Oct 2010
Posts: 5,132
Likes: 45
From: Columbus, Oh
Well there you have it. Stand corrected again. My apologies Joseph.
Logistics Pro
Joined: Jun 2012
Posts: 4,063
Likes: 2
From: Southeastern IL
And of course the pre-92 pedals are a dime a dozen... They kinda wrap around the steering column while a post-92 is just a flat plate.
Not to thread jack but is it possible to swap bellhousings on these ZF5s or is it all a single cast piece
Not to thread jack but is it possible to swap bellhousings on these ZF5s or is it all a single cast piece
Post Fiend
Joined: Dec 2010
Posts: 10,121
Likes: 3
From: Orrville, Ohio
It's all one piece. The transmission just needs to be from a diesel. Even the ZF5 used on the IDI's would work, it just has a different bolt pattern than the gas engines used.
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