Have a 1994 Ford F-450 with a toasted E4OD transmission and want to replace it with a medium duty Fuller transmission (FSO-6406A). I want to use a 14" clutch and all I am able to find for a Ford 460 is a 13" clutch. The Ford 7.8 diesel has a 14" clutch but have no clue as to what the crank pattern would be.

I have performed this swap (2008) on my 2001 Dodge. Straight forward install. Fab was a clutch bracket, trans mounts, 2" body lift and shortened drive shaft. The 460 will involve a little more fab. I have a brand new 6 speed trans, flywheel housing, clutch, hyd slave and pedal assy, so I'm ready to go.

What I need help with is finding a flywheel that will work for this swap. As I see it, my options are;

Find a way to use/redrill a 5.9 flywheel
Try to adapt a 7.8 flywheel and redrill
Fab crank spacer and drill for 460 and 5.9 and fab spacer to place between engine block and 5.9 adapter

I welcome any suggestions and links

 

429 Lima truck motor parts might be the answer.

 

Why the 14" clutch?
429 Lima truck setups use a 13" clutch, so does Power Stroke Diesels and 5.9 Cummins
Why not just swap in a ZF6, it'll handle anything a 460 can throw at it.

 

ZF6 is modular and diesel pattern, not BBF pattern.

 

Adapter plate.

 

You need D9TE6380AB which is the castle style flywheel. This gets you the 13/14 clutch options. You will need the pressure plate,clutch disc and the SAE 3 engine adapter as found in the F800 series trucks with the 429 if you want the best chance of finding a full setup. Be warned the starter switches to the passenger side with the adapter. Also for reference the 5.9 Cummins and 7.3, 6.0 PSD also had a 14 inch clutch when used in medium duty trucks and those parts are very easy to get.

 

Spent a little time looking. Closest I got was DIY.

 

I currently have a 14" DD clutch in my 2001 Dodge 3500. I usually haul heavy and the setup with the Fuller 6 speed works great. No problems in 10 years.

I have all the parts for a conversion (FH, flywheel, clutch and a brand new FSO-6406A O/D transmission).

I took my 5.9 flywheel to a local shop to have the 5.9 bolt holes tig welded. I have also lined up a shop to drill the hole pattern in the 5.9 flywheel to match the 460 Ford pattern. Cost should be around $225.

Nice part of the Fuller is that I have made an adapter for a 4 X 4 application





I'll keep you posted on how it all turns out.

 

Is a 460 internally balanced or does it need a weighted flywheel.

 

External balance started in the 1979 model year.

https://www.ford-trucks.com/forums/8...-balanced.html

 

Ok Thanks.

 

I'm curious what the stroke length on the slave cylinder is for the Fuller. I'm about to fab a bracket to hold the cylinder but not sure which one to use. My throwout arm seems to have a ~2" swing

 

The slave cylinder on all trucks is an OEM product and varies widely ..... that said, the Fuller clutch only requires a 1/2" separation at the disc/plate. The setup of the linkage or slave/lever actuator is what makes it a soft easy clutch or a bear to depress. Also an OEM add-on.

You don't have to spend mega-bucks for slave cylinder. Recommend that the slave have a larger bore than the master. I used (made my own) one out of 1-1/8" brake master ($10). and a $35 Volvo truck slave.