5 Speed Trans Swap - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 21 (permalink) Old 10-18-2007, 01:06 AM Thread Starter
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5 Speed Trans Swap

My auto is done well maybe, I dont really care I just want a 5 speed. Thats what I wanted before I bought this truck and thats what i should have got. I got most of the stuff figured out but have a few questions.

First Can I still get the engine/trans adapter for the zf-5 from ford? And where can I find out what kind of hardware I might need that won't swap from the auto to the manual such as bell housing bolts?

Also the T-case will bolt up right? I'll just need new drieshafts?

Thanks!

1997 2500 Cummins 4x4 230k
Grinded Fuel Plate, AFC full foward, Starwheel Adjusted, Staightpiped
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post #2 of 21 (permalink) Old 10-18-2007, 01:12 AM
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Last I knew you could get the zf trans to t-case adapter from Ford. I can not remember the part number though. When I did my swap years ago, I am pretty sure I used my auto bell housing bolts. I would reccomend getting a one piece flywheel conversion as well. Contact Sogrand, Dan, for more info and really good prices.

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post #3 of 21 (permalink) Old 10-23-2007, 12:36 AM Thread Starter
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Thanks, I was planning on contacting Him for prices. Do you mean the Trans to motor adapter? I thought there was some kind of motor adapter plate and the t-case will bolt right up to the back.

1997 2500 Cummins 4x4 230k
Grinded Fuel Plate, AFC full foward, Starwheel Adjusted, Staightpiped
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post #4 of 21 (permalink) Old 10-23-2007, 01:42 PM
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I dont think there is a difference in the adaptor plate, I believe they are the same.
as for bell housing bolts use the auto ones.
ditto on getting a solid flywheel conversion, all the bolts will be there for that. just remember to take the spacer off of the end of the crank, auto uses it, 5 spped dont.
transfer case will bolt right up.
the cross member should be the same
and driveshafts should also remain the same.
dont forget the pedal assembly, the master and slave cylinder,
plug is already on the firewall for the clutch start switch, but ya need the switch
also need new cpu or have jody at dp tuner reflash it.
steering column can be redone from auto to standard.
and dont forget the plate for the floor, ya either need a standard one, or cut the old one out.

1996 psd 5speed 4x4 cc 8' bed, 3" body lift, 35's swamped, dp-tuner, intercooled, custom fuel system, no fan, and a few other goodies, 263k. 349.2hp sold
2003 7.3 4r100 4wd sc 8', xlt 20th anniversary edition
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99 v-10 4x4 sc sb auto 275hp gas guzzler
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post #5 of 21 (permalink) Old 10-24-2007, 01:35 AM Thread Starter
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Cool thanks, I think the flexplate seperated from the crank so I dont know if those bolts will be there or not. I hope the end of the crank isnt messed up if thats the case.

1997 2500 Cummins 4x4 230k
Grinded Fuel Plate, AFC full foward, Starwheel Adjusted, Staightpiped
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post #6 of 21 (permalink) Old 10-24-2007, 02:09 PM
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what do ya mean by flex plate seperated??

1996 psd 5speed 4x4 cc 8' bed, 3" body lift, 35's swamped, dp-tuner, intercooled, custom fuel system, no fan, and a few other goodies, 263k. 349.2hp sold
2003 7.3 4r100 4wd sc 8', xlt 20th anniversary edition
stock cept for duals. 260k sarted out as a 2wd xl work tk
Early 99 CC dually 4x4 4r100 dark lights, dark windows, stainless simulators
99 v-10 4x4 sc sb auto 275hp gas guzzler
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post #7 of 21 (permalink) Old 10-25-2007, 02:10 AM Thread Starter
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Well I was going down the road and lost all gears and it won't start. I pulled the inspection cover and the flexplate spins when you hit the starter but the engine doesnt turn over. I guess I'll see exactly what happend when I pull it, I dont know if the bolts sheared off or if the flexplate broke or if the bolts just backed out somehow. Or maybe the end of the crank broke off, which would suck.

I have another question though, what do you do about the Steering column lock? I was just gonna pull the shifter off and get the manual steering coloumn plastic cover. Will that be good or do I need to ground out some switches or somthing?

1997 2500 Cummins 4x4 230k
Grinded Fuel Plate, AFC full foward, Starwheel Adjusted, Staightpiped
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post #8 of 21 (permalink) Old 10-25-2007, 02:04 PM
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chances are that the flywheel is cracked around the bolt and looks like this one
I have seen it before. the fix is a new flexplate, new bolts and a new spacer.

as for the column, take the shifter and tube out, and replace the covers with standard, but you will be missing the lockout button that the standards have
there is no wireing difference than the extra harness for the OD light.
Nick
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1996 psd 5speed 4x4 cc 8' bed, 3" body lift, 35's swamped, dp-tuner, intercooled, custom fuel system, no fan, and a few other goodies, 263k. 349.2hp sold
2003 7.3 4r100 4wd sc 8', xlt 20th anniversary edition
stock cept for duals. 260k sarted out as a 2wd xl work tk
Early 99 CC dually 4x4 4r100 dark lights, dark windows, stainless simulators
99 v-10 4x4 sc sb auto 275hp gas guzzler
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post #9 of 21 (permalink) Old 10-28-2007, 09:12 PM Thread Starter
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Cool, I hope it does look like that one. So should I put in park or anything before I take the shifter out? Also I can just Hang the Trans harness up and out of the way and tape it off right?

1997 2500 Cummins 4x4 230k
Grinded Fuel Plate, AFC full foward, Starwheel Adjusted, Staightpiped
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post #10 of 21 (permalink) Old 10-29-2007, 01:54 PM
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yep put it in park, as for the harness, just put it off to the side, 5 spped has no wires other than reverse lights.

1996 psd 5speed 4x4 cc 8' bed, 3" body lift, 35's swamped, dp-tuner, intercooled, custom fuel system, no fan, and a few other goodies, 263k. 349.2hp sold
2003 7.3 4r100 4wd sc 8', xlt 20th anniversary edition
stock cept for duals. 260k sarted out as a 2wd xl work tk
Early 99 CC dually 4x4 4r100 dark lights, dark windows, stainless simulators
99 v-10 4x4 sc sb auto 275hp gas guzzler
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