As a lot of you know I have just completed the swap from a 4r100 to a ZF6 in my 1999.9 F-250. Here are the steps I have taken to do so.
There are 3 ways to do this. Get a wrecked donor truck from a junk yard. This would probably be the easier way if you have the money to have tied up in a truck. Andy (Moore20017.3) on PSN did this and once he was done with the swap made money.
I on the other hand didn't have the time or money to get another truck. So I got all my parts piece by piece to complete the swap.
Another way to do this is to get someone that is looking do a manual to auto swap. There are lots of people doing this also.
Here is a list of parts you will need.
6 Speed floor hump out of junk yard truck.
Clutch Pedal Assembly
ZF6 Transmition and Transfercase
A pre-bleed Master/Salve Cylinder kit from Ford
New clutch and flywheel I also recommend the upgraded Clutch Fork from South Bend
Manual PCM (Optional)
First off the ZF6 is a much taller transmission then the 4r100 therefore I had to find a floor hump out of a Super Duty that used to have a manual. I would look in a junk yard for this. I found mine for $100. If you look at my pictures below you will be able to tell how big you should cut it to make it work right.
Once you have the cut out hump from the manual lay it over the floor hump in your truck. Mark the out side edges all the way around with a marker so you know where it will line up at. Once you have done this go in about 1" from them marks and make the marks where you are going to cut. This will be your lip so you will have something to screw the new floor hump 2 when you go to install it.
Here are some pictures.
With the old floor hump out of the way there is LOTS of room to get to the tranny bolts. This is one reason i didn't bolt the floor hump back in place yet.
Time to remove the old auto tranny. If you are trying to do this swap then you probably have enought understanding to remove the old tranny.
Once the old tranny is out of the way you can remove the old flex plat. Also remember to remove the spacer that is behind this as it is no longer needed with the new fly wheel. Also remove the spacer that is between the transmission and motor at this time.
Now its time to install your new clutch. If you got your clutch kit from South bend
it came with a new flywheel and everything you need. If not make sure you have the correct flywheel and I highly recommend putting in a new pilot barring at this time if it is a used flywheel. The one from South Bend
already has a new one in it.
You are now ready to install the new zf6.
BUT FIRST!!!! You will need to masure the pins coming out of your engine. and then masure the cast on your zf6 and make sure that it will fit with out hitting. There are different casts of the ZF6 Some will fit with out modification like mine and some you will need to grind down the pins on the motor so they will not hit on the ZF6.
Make sure you do this. If not you could crack the housing on the ZF6 and it would be no good.
Now you can install the ZF6. Here are some picture of how I did this. Don't laugh to hard. I didn't have a tranny jack.