Auto to Manual Transmission Swap (with donor truck)
 

I have a transmission that is failing and hate automatic transmissions. I would like to swap to a manual trans instead of rebuilding my current trans. I believe it is an E40D with overdrive. I love my truck, it is a bit rare and will not be easy to find/buy the configuration I am looking for which is why I am looking to do this.

In looking for a donor car, what year ranges will bolt on to my 1991 f-350 7.3 IDI Diesel 4x4 4Dr Bronco? Does the donor need to be exactly the same as my truck? for example does it need to be 4x4 and crew cab? I know some ford suv's used truck parts, will any of those work in addition to a truck?

Here is what I expect to take off of the donor from my research?

• Pedals/Pedal Assembly
• Brace for Pedals
• Slave Cylinder
• Cross Member
• Shifter
• Misc Hardware
• Lines
• Instrument Cluster?

It is a IDI diesel so there are no computers for manual trans I believe.

Thanks, any help is appreciated?

David

You can get a pre-bled master/slave cylinder combo from LuK and many others that will save you time and effort. Plug and play. Comes with the lines.

Get the updated shift fork from Ford, as well. It's beefier.

You're going to want a ZF5 with a BW 1356 if you wish to retain your 4x4. Front and rear driveshafts may need to be changed, or you may be able to use what you have. I did my swap on a 2wd truck, so I needed the driveshaft from the donor vehicle, but it was a perfect fit.

You say you've got a F350 Bronco? I'm assuming it's a conversion that had the bed shortened? This is going to affect driveshaft length as well. If you have a regular F350, just looking for an F350 the same config as yours that's manual and take the transmission, transfer case, driveshaft, and crossmember.

Your truck doesn't have an onboard computer for the motor, just one for the E4OD, you can just take that out. Instrument cluster should be able to stay the same.

Ok, will need to research all of this. I have a feeling this is going to take me months to finish. Have to learn everything, don't know any of this and never done anything like this at all. My extent to repairs is brakes, radiator, etc. But I think I will get it eventually.

For example, I know of the ZF5, but not sure of the BW 1356. Shift fork I can order. My bronco was made by Centurion for Ford. So it is shortened some, guess that will mean I need a drive shaft also. Can I get a ZF5 from any Ford vehicle?

Thanks,

David

If you can get all of the parts before you begin, you can get it done in a couple of days.

My swap took me about three days total, working a few hours each night to make progress.

The ZF5 must come from another 7.3 to make things easiest. The BW 1356 will be one of your transfer case options. I scored my ZF5 with transfer case, driveshaft, and transmission tunnel cover with hole for the shifter for $700. Spent about another $400 in new parts like clutch/flywheel kit from LuK, master/slave cylinder set (should come with the neutral safety switch), pedal assembly, and fluids for the transmission and transfer case.

There will also need to be some wiring that must be done to get your reverse lights working, and potentially for cruise control (if you have it) and 4x4 lights. Neutral safety switch should be easy, just pull the jumper from the wiring harness under the dash and plug it in to the NSS. I'm assuming you '91 has all the wiring in it already from the factory just like my '96 did.

There are lots of threads about this subject if you will do a search those will help you.

As for finding a 1356 T case, I'm using the same one that came stock in my Bronco (with a 302) behind the 7.3 ZF5. Any 1356 should mate up to a 4x4 ZF5, they may in fact be the same between all the trucks.