Automatic to Manual ... Advice needed
 

Hi Guys,

as a lot of you here, i do not like my E40d and i want to swap it to a manual.
Besides the obvious , ie transmission, clutch, flywheel, and pedals with cylinders, what else will i need ? i heard , the Trans tunnel is taller on a manual and needs to be modified?
How about the Starter ? will it still fit? PCM ? how do i modify the Harness?Driveshaft ok? :-huh

I been reading, a lot of people like the ZF. As a stupid question here: does any ZF , 5 or 6 speed from a diesel fit (95-2003) Was there another standard transmission used by ford , i need to stay away from ?

Thanks for any input / guidance.

BTW, my automatic still shifts fine, just don’t like auto in a diesel :)

ZF5 is the one you want. ZF6 take s more parts and time... driveshafts need to be modified. You can use your auto pcm.

Bill has a thread with the necessary wiring changes. You need the manual crossmember too. Think I'm missing something, but I'm only phone.

i guess if someone knows of a good write up, that surely would help :-)

It would be best to get a manual trans harness and do a couple simple modifications to it. It's easier than modifying the auto harness.

does any year ZF 5 speed fit as long as it is a 7.3 OBS?
So i need the driveshaft or what mod would i need to do on it?

since i plan on rebuilding the turbo at the same time and change the down pipe, would it make sense to remove the ebp valve or can i convert it into a exhaust brake?

If you can, get the floor pan with the hole in it for the shifter. If you can't get it, you can use the one you have, you'll just have to cut a hole in it for the handshaker. The tunnel and pan are the same height, it's just easier not to have to cut the hole in the floor pan since that section unbolts from the cab anyway.

So the list should be:

-Transmission from a Ford diesel (6.9 IDI, 7.3 IDI, 7.3 PSD, doesn't matter)
-Clutch and pressure plate - it's recommended to upgrade to a SMF during the process
-Pedal box from a '92-'97 truck (F-150 (92-96) ,250 or 350 it just has to be the OBS style not the newer '97 F-150 style) -- it's also wise to do the heim joint fix now too to eliminate that bushing issue in the future
-Clutch master and slave cylinder
-Drive shafts from a manual truck with the same cab configuration as yours (if you can get them -- if not you will have to have yours lengthened and shortened by I believe 5 & 3/8" -- Bill knows for sure )
-Manual PCM if you can get it (optional but makes the swap cleaner)
-ZF5 Transmission Crossmember
-Manual Transmission wiring harness (again, optional but makes the swap simpler)
-Clutch Master Cylinder safety switch
-Manual Transmission Truck Steering Column (or you can swap the covers and key cylinder lock lever onto your Auto column)
-Manual gauge cluster (or at least the blank panel that covers the auto shift indicator)
All the consumables you'll need (fluids, bearings, etc)
A few buddies and a cooler or fridge full of the cold beverages of your choice and you can have it done in a weekend.

Also, I think many of the guys would agree with me that having a transmission jack available makes this a lot safer and easier that wrestling that thing in there by hand or on a floor jack.

That's pretty much it as far as I can remember. Bill (ReBilld) is the expert on this. He has done 3 or 4 of these now. If I am forgetting something I'm sure he can point out what it would be.

The starter from your E4OD truck is the same, so you can reuse that as well.

Honestly if you can, get a parts truck and pull all this stuff from it. Having it all there in one place makes it a LOT easier and then you can sell the balance of the truck as parts (or keep them as spares).

I don't know if I would consider myself an expert at much of anything Nate LOL! But thanks! You pretty much covered the list, except the drive shaft needs to be lengthened 5 3/8", and that is on the 4x4s. I've never swaped a 2wd, so that measurement may not be correct either. The best thing to do there is measure the 2wd E4OD and the 2wd ZF and what ever the difference is, make the drive shaft that much longer.

I'm finishing my swap up right now. I bought the whole package from a guy who was putting an e40d into his truck. I agree with Nate though about getting a parts truck.

It was nice that everything was already removed for me, and he did a great job labeling it, but it can be tough sometimes to figure out how things go together since I didnt see them come off the old truck.

Did you get the text I sent you today Rick?

Not yet. I havent been into cell service yet. I will be this afternoon. I'm burnt out right now from just too much going on so my swap has stalled for a few days to recuperate.

That's my problem Rick, I still don't know what they did to my truck. I was parts running and the darn thing was in when I got back! Lol

A little birdy told me there is a spot somewhere that says "Bill was here". Happy hunting :-X22

thanks guys,
that is quiet a bit of info. Just hope i will get all parts pretty soon though.
Can anyone confirm the driveshaft modification for the 2wd, it it is necessary?
Also, what kind of electrical changes on the wiring do i have to make and can i use my pcm as is ? And how about the ebp valve.. who is using it as an exhaust brake? or is it not worth it?

thanks

Most say the benefits aren't worth it and just delete it. The e40d is about 5 inches longer so your rear shaft would need lengthened.

deleting the ebp would sure let the engine breath better. I guess the best is finding a donor truck, where i can use the driveshaft as well.

Lol. The second day was quite stressful for numerous reasons and that SOB had the nerve to say the driveshaft was cut improperly. The nerve! I almost smacked him with a large wrench!

Which SOB are you referring to? :D

Ill give you 3 guesses and the first 2 don't count!

:-missingt...............

Thanks for setting my measurements straight, Bill. I corrected my post so no one gets wrong information from it.

You ever went to a salvage yard that usually don't have anything you need ? Well I stopped this morning at a u-pull place and they just gotten two diesel in. I a 95 and a 96 both standard . Well went back home , called a friend loaded tools and back to the junkyard . Some guys were already pulling the tranny on the 95 so I went to work on the 96 . 3 hrs later I had a 5 speed zf in a good condition, a a steering column, all pedals, harness , PCM , driveshaft , flywheel and clutch . Got everything but the actual shifter . It was gone and could not locate another one . Paid 190 for everything:D . And deem it was hot out there

Wow. Even if the ZF needs rebuilt you got yourself one hell of a deal! :-X22

In and output shaft of the tranny have absolutely no play . The shifter linkage is tight as well . Clutch package only had minor wear on it. I did noticed however that the bearing in the flywheel was bad . Well I guess I can get that at the parts place. But where do I find a shifter?

Dang! That is one heck of a score! I paid considerably more for my swap...

That was a steal! You need to go buy a lottery ticket, cause you're one lucky guy! LOL! Congrats on the parts find! :-X22

thanks guys,

but the luck was pnly, because they had to diesel truck sitting there. the pricing at the local store is extremely low, and is regardless of where the part comes from... so if you buy a transmission from a pinto or a ford diesel, its always 65 plus core.
that one 95 still was somewhat complete, engine and all. but hpop was pulled. still had valvecovers on and injectors on. it was tempting, but for injector they charge 25.

i might scan and post their price list..
but for now , i got to purchase more material, before i attempt the whole job

Wow, you got one heck of a deal on that stuff!

Can anybody verify whether the shifter from a 5 speed F-150 would fit on this ZF5? Some of the gassers got the ZF and some got the M5OD but I would think (guessing here) that the shifter from a gasser (F-150,250, or 350) with a ZF should work just fine.

Nate - I'm almost positive that any shifter from almost any ford with a manual transmission from the 80's and 90's will be interchangeable - maybe even more years. they might not all be the same shape - some of the older ones were quite tall, but they should all have the two-hole mounting configuration at the bottom. I know my old 97 explorer shifter was the same as my current F250 gasser (with ZF5). the boot is probably different, though - or maybe not...

just measure the c-to-c distance on your tranny stub and check at the yard, right? even if the holes/threads are different size, that'd be easy enough to make work....

Any chance they have a extra cab long bed manual? Either 7.3 or 7.5
I can't find a driveshaft anywhere

This is a good read.

https://www.ford-trucks.com/forums/1...peed-swap.html

our local salvage yard had a 95 f350 cclb dually and a 96 ext cab long bed.. thats where i got my 5 speed from. the Driveshaft is still in the junkyard truck for the ext cab.Also the crossmember is still there. :D

the only bad on the driveshaft was a damaged center carrier bearing.
As per their Price list they charge 17.99 per section, plus tax

Where are you located?
Would you be willing to get it and ship it?

its probably pricey to ship. I am in Mississippi. did you needed 2wd or 4wd.. because the truck was 2wd?

4wd
thank you though

As long as it's from a ZF it will work. The shifters on the M5OD have a flat sided pinch bolt at the bottom instead of the two bolts like the ZF.

Duh, yeah I should have remembered that from the M5OD in dad's Ranger. I remember it now.... ;)

I have a 4x4 eclb rear driveshaft I may be able to part with in the near future - no promises, though. its from a 96/97, though - with the 4-bolt flange on the front of it.

If I wind up buying a crew cab instead of doing my e4od to zf5 swap on my extended cab, I can part with the driveshaft. you'll have to wait until I find my next truck, though :-)

I had a heck of a time finding this one, though so I understand your difficulty.

this one is somewhat rusty on the extererior though, but the center splines and carrier bearing seemed OK and all the balancing weights are still in tact...