Auto to ZF6 Conversion Part 4
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- Опубліковано 22 вер 2022
- The 4th and final video on swapping a ZF6 into a Ford Super Duty.
Part #'s used in this video:
T-Case Shift Boot - F81Z-7227-BC
Upper Trans Shift Boot - F81Z-7227-BB
Lower Trans Shift Boot - F81Z-7227-AC
Lower Boot Retainer - E7TZ-7D152-A
Shifter Bolts - M8x1.25 - 35
Shift Lever - 4C3Z-7210-AA
Shift Knob (trans) - F81Z-7213-AA
Black Upper Steering Column Cover - YC3Z-3530-BB - Авто та транспорт
I’m right in the middle of this swap and I’ve probably watched this whole series probably 20 times and it’s helped ALOT
I'm glad it's helping. That's why I make these videos.
Working on zf6 swapping my 99 as i write this, and this series of videos had made the swap a lot easier to carry out.. the only issue im having right now is finding the floor pan hump for the zf6..
And the mention about replacing the auto-trans input shaft on the transfer case with the input shaft from the manual trans splined input shaft was about right, but found an input shaft for relatively cheap and figured it was a good time to check the chain anyway, with 300k on a very heavily used truck, it was a good thing to check out.
The entire zf6 swap was carried out because i actually use my truck for truck things, and got tired of replacing automatic transmissions that werent holding up to what i needed, even after wasting $6k on a built transmission, it definitely lasted longer than stock autos, but started slamming into 2nd gear and very shortly after that, would hold 1st and then almost redline before very unhappily shifting into 3rd.
Really great video! Im working on a OBS 1997 powerstroke crew cab. Its been used as workvehicle in a large mine operation up north here i. Sweden. so its rust free. It had some dents and scuff so I had to fix the body and its repainted. Only about 110000 miles on it, but probably a lot of idle hour on top of that. It has zf5 original and only 2WD. I actually got hold of a front axle dana60 from a superduty. Later I bought a ZF6 with a transfer case so eventually I will make the switch. Its kind of hard to find parts for a Ford here in Sweden, US Ford never had a service organisation her so GNC and Chevy had so they are more easy to find used parts for, so that gear box was an amazing find. Because I had a hard time finding an old non attached transfer case which was my first plan…
Anyway the transfer case was electrically gear switched and I wanted a manual with a stick. So I remade the electrical gear switch by taking out the motor and some gears and made it a manual one by making some parts in my shop, if I want I can still redo it back to a electrical again. Also found the stick lever brackets from an older Ford and attached them to the gear case. If im not mistaking I believe theres a difference inside the manual gearcase and the electrical? I read that the electrical has some kind of syncronization for shifting the gears. I dont think thats a negative thing on a manually shifted?
Thanks and greetings from Sweden
Thx for the vid. I actually was looking for a video like this. Super helpful
Glad it was helpful! That's why I make these videos.
I spent nearly 50k completely restoring a 2000 f350 cclb and did the zf6 swap. To get around cutting up the floor in the automatic cab, I installed a body lift and it cleared perfect even though it’s not ‘meant’ for the diesel model. Also makes getting at the bell housing bolts and turbo alot easier!!
50k??? Holy crap you put some cash into that thing! You got a better truck than spending 50k on a newer one though! A body lift would definitely work. I prefer stock height though so a body lift wasn't even a thought for me. How does the body lift effect alignment of intercooler pipes and stuff? I've never installed one.
@@darkhorseautoanddiesel that was my exact thoughts, better spent on an older truck but was one hell of an undertaking!! There’s enough give in the intercooler pipe boots it worked just fine, but I’m sure that’s the main reason they don’t recommend it for the diesel trucks, it does take a bit of finessing to get them to sit right.
@@Bear1097 No emissions BS to deal with, and much simpler on the electronics side. Complexity is the enemy of reliability, and a 7.3 is complex enough. At least they can still be diagnosed and repaired at home with mostly simply tools.
I always wondered if you'd have to modify the pipes, good to know that you don't.
@@darkhorseautoanddiesel EXACTLY!! Many people think I’m crazy for it, but thats always what I say. Just modern enough where you have the best of both worlds with the electronic controls and simplicity, and with some reasonable upgrades makes all the power a guy could need.
@@Bear1097 Exactly why I own 2 of them, and why I'm never selling either. One of them has 530k miles and counting.
I have a e99 cclb 7.3/zf6. I enjoy watching your zf6 swap videos. They are very informative. Any issues with using the bronze pilot bearing and what brand clutch/flywheel did you use?
No issues so far. I haven't had a reason to pull the transmission yet to inspect it, but I have no reason to believe that there will ever be an issue. Those bushings were used on cars for years, I feel like they probably stopped using them to save manufacturing costs (that's just a guess though).
The clutch is the biggest single disk clutch you can get from South Bend. The next biggest one is a dual disk. It was used when I put it in my truck, it was on the parts truck I used. However, I was told that it had only a few thousand miles on it, and I have no reason to doubt the guy I bought it from.
what a GREAT video. thank you
You're welcome.
I imagine that the obs would very closely mirror your superduty, correct? When this e4od kicks it I’m going zf6 if possible.
I just watched your whole series of this swap and im wondering if you happen to know if this is basically the same for the 6.8 v10. Mainly wondering if driveshafts are going to be the same length. Im looking at a donar truck with the zf6 im wanting to get to do this but want to make sure everything will work
I’m doing a swap on my 02 now I got my pcm reflashed to a manual code but I’m not able to get my truck to start I did jump the grey plug. My 02 automatic harness doesn’t have those two larger wires they’re all the same size. I know there’s some differences between 99-01 and 02-03 but the 99 manual harness plugged right in no issues. Not sure what else isn’t letting it start. Thanks
Have you checked the wires under the dash for the clutch safety switch part of the circuit?
Hey Dark Horse, I have not been able to get a 7.3 Engine wiring harness for my 2000 with a ZF6. I'm hoping that if I buy the Automatic harness it could be modified. I think that would be a desirable video for many viewers. Thanx
I am currently doing a swap on my e99. Do you have any info on using the electric transfer case? Also did you have to add a coolant temp sensor?
I did touch on the transfer case briefly at one point in the video, however I'm guessing you need wire colors. Unfortunately I'm currently about 1100 miles from home where that is written down, and will be for a few more weeks. If you're still working on it when I get home I'll see if I can help.
The 2nd coolant temp sensor is only on 02 and 03 trucks, and my truck is a 2000, so no, I didn't have to. However, I'd guess you'd have to on 02 and 03 trucks. I'm not sure if it would make any difference or not.
I am getting ready to swap a auto for a manual in a 2007 and the donor truck is a 2006 will i be able to use the pcm from the 2006 and my 2007 has the electric 4 wheel shift knob, that extra info on that would be appreciated Thanks Todd
I've never done a ZF swap on a truck of that year range, so unfortunately I can't give any definite answers. My video is only really relevant to trucks that have a 7.3L. I can however give you my best educated guesses, for whatever they are worth, just don't take them as gospel, just suggestions.
I would think you could use the PCM from the '06. I don't think a whole lot, if anything, really changed between '06 and '07. As far as the electric shift, I believe it will require similar work to doing it on a 7.3 truck, which means a bit of modification to the wiring harness to get the proper inputs, i.e. brake signal, shift signal, and clutch signal. If you're switching to manual shift like I did, then you really don't need to do much of anything except changing the reverse light plug to go to the ZF switch instead of the auto's DTR sensor.
I'm curious to know the answers myself, so if you think about it, keep me updated on your progress. I might end up doing a swap on a truck of that year range some day myself.
I'm planning to do mine I have 03 powerstroke I'm buying a 1995 f350 I learn a lot on the videos I got lost on the transfer case I have both manual and automatic which one I use thanks
On late 99 to 03 trucks, the input shaft is different between auto and manual trucks, the spline count is different (don't ask me why, I don't know, and it makes no sense to me either). As far as the later model trucks, I'm not 100% sure, but I'd guess it's probably the same way.
Almost done with my 2000 7.3 excursion zf6 swap. Can I use the trans wires for the manual?
Yeah you can, with some modification. That's what I did on a buddy's truck many years ago. I actually ended up cutting most of the wires off the harness since they no longer get used. Had to remove the plug for the DTR sensor and add the reverse sensor plug for the reverse lights to work, and do some more splicing to get the ESOF transfer case to work.
Obviously the easiest way to do it (and my preferred way since ESOF can be finicky, and I like reliability) is to switch to a manual shift transfer case, but keeping the ESOF is definitely possible.
I bought a 2002 zf6 4x4 manual transmission wiring harness will that work or do i need to have the engine one as well. And i also have the manual pcm for the truck. Will i be good?
You should be as long as your truck is a 2002 or 2003. The engine harness is the same, except for some reason 2002 and 2003 manual trucks have a 2nd coolant temp sensor. I've never heard of anyone having issues by not adding it though, although that doesn't mean no one has.
@@darkhorseautoanddiesel I swapped out my auto harness for the manual everything matching up except for the one grey plug which I jumped but I'm having trouble starting it. I put it in start position and nothing. I'm confused. Would it be the neutral safety switch the small grey box under the steering wheel if so what do I have to do to it
I also swapped the auto PCM for a manual one.
@@crenshawmings8660 Do you have a clutch switch installed? If not, did you leave the jumper on that plug that the auto trucks have?
I have a 2003, 7.3 Powerstroke with ZF5, 4x4 manual, but my truck has a lack of power too. Do you have the part number for PCM for manual? Which is the best web site for purchase the PCM for manual?
Regards from Costa Rica!
Did you have any fuel mileage decrease problems because I've read that some people have and there mileage drops to like 8mpg
I haven't really noticed a change in either direction. I always reset the trip meter every time I fill up, and I seem to get about the same amount of miles per tank as before. If it has changed, I'd have to guess its a minuscule amount better. However, I don't keep track of miles per gallon much, I usually go by smiles per gallon, especially when I get the Stang out.
If I already have a manual transfer case with my automatic transmission, would I need to replace the transfer case with the new manual transmission?
Yeah. The transfer case has a different spline count between automatic and manual transmissions. The transfer case being manual or electric shift doesn't matter. Both electric and manual shift transfer cases came behind both automatic and manual transmissions. The difference is the transmission, not how the transfer case is shifted. Hopefully that makes sense.
It does. Thank you
Hey man I know you did. This awhile ago but out of curiosity would you know anything about the wires for the 4x4 I bought the truck swapped to zf6 from auto and was courious if you had anything available to help me get this electric shift b.s to work any help would be appreciated
Every 99-01 7.3 I’ve ever had, it’s been an issue with the GEM module. I got fed up and pulled the wires from the relay, and ran them to a 3 way switch. The relay grounds the circuit to engage the tcase motor. BUT need to be extremely careful with how you set it up so you don’t accidentally shift when not desired. I have a secondary ‘safety’ switch setup in case it gets bumped accidentally going down the road!!
I'll have to look and see if I can find the paper I wrote some notes one back then. It was a pain doing the ESOF. I used the factory automatic wiring harness and changed a bunch of things around. It did work perfectly when I was done though. It just took about a day to get all the wires figured out and rerouted. I'd definitely suggest rewatching the section where I talk about it and pay close attention to get the basic idea of it. I'll see if I can find that paper in the next few days and report back with my findings.
@ Dark Horse, did you ever find that paperwork for the wiring we need to make ESOF work? I just got my 2000 truck all together awhile ago, and found my 4lo isn't working. I'm guessing it's the neutral signal it's not seeing.
I have a 98 Expedition with 5.4 can I do this swap on it
With enough time and money, just about anything is possible. If you had an Excursion with a 7.3 you could follow right along with this series with very little differences.
However an Expedition is totally different animal. If you found a 5.4L pickup with the manual trans as a donor vehicle, you could get it to mate up to your engine, the clutch and flywheel might swap over (this would need to be verified) and the bellhousing pattern is the same. The floor pan will probably have to be totally custom made on your truck and you'll possibly lose your center console, or at the very least have to do some serious modifications to it.
Mounting the clutch pedal might be a challenge. The Expedition is based on an F-150, so there might be provisions on the firewall (due to shared components) to mount the pedal, but I'm not sure on that and this would also have to be verified. If there is no provisions already there, you're going to have to custom make it.
If the ZF6 is longer (I'm not sure, never compared) than what you have in your Expedition (4R70 if I remember correctly) you're probably going to have to have your driveshaft lengths changed. Rear will likely have to be shortened and the front likely lengthened. You may have to make a custom transmission mount too.
Possible? Yes.
Worth doing? That depends. If you have a desire to do a crazy build that probably no one else has done and don't care about the fact that it will probably cost more than the truck is worth and probably won't increase the resale value, then go for it. I'd actually like to see it done. I like custom builds, at least when they are done tastefully and correctly (not SEMA garbage). If you're just looking for an affordable alternative to getting your auto rebuilt, don't, just rebuild what you have.
I have a 2000 2WD with 265k on it. I had thought of doing this swap but I think I’ll go to Arkansas and have BTS build me one. I think I will do a 4WD conversion though.
What's kinda funny is that this truck used to have a BTS in it. Long story but the short version is that the trans in my work truck (that I drive all over the country some times) was about to fail, so I swapped them out since this truck rarely leaves my local area (I'd rather have a trans failure close to home rather than in the middle of the desert somewhere). I've had this truck since 2007 and wanted it to be a manual since day one (wanted a manual, but settled for an auto).
i need a tan column cover! reat series I'm about to get going on my 02 lariat
I had a tan one from my parts truck, I probably threw it out 🤣 If I remember I'll look. Not sure where you are located, but if I have it I'd rather see it go somewhere it'll get used instead of taking up space.
I'm in NJ so if you find it let me know and I'll pay for shipping or whatever . Thanks@@darkhorseautoanddiesel
How long did it take you to do this trans swap?
About a week or so although I did a bunch of other stuff while the truck was in the shop. On the other hand, I also didn't work that week so I was able to stay pretty dedicated to it. If a person had all the parts ready and stayed at it pretty well, it could be done in 3 days pretty easily.
What is the website you ordered all this from ?
A lot of it came from a parts truck I bought. The few missing parts and ones that just weren't in good enough shape for me to be satisfied with being in one of my most prized possessions I got from Rock Auto and White Bear Lake Ford. All of the OEM parts shown I got from White Bear Lake. I don't think I got much for the swap from Rock Auto, I think the stuff I got there was "while you're at it" kinda things like uppipes and stuff.
parts.autonationfordwhitebearlake.com/
www.tascaparts.com/ is another good place. You'll have to look at both and compare prices and shipping to see which is cheaper based on your location. White Bear Lake is closer to me so the cheaper shipping makes them the better option for me.
Silly question..if i flew you to canada would you be willing to give me a hand with an e99 f450 auto to zf6 :)?
I do have a valid passport....
What about lodging haha
@@darkhorseautoanddiesel i mean id have no issue paying for a hotel or what ever ha or my home aslong as you wont kill me and my family
@@Sylvainrewhere you at, I’m in Alberta if you have questions