5.4L 5 Speed Conversion

[TactialMonkey]

So far I have done the pedals and shift boot but the transmission is soon to come! There are 2 transmissions for the F:150 the M5OD which is a 4.6L transmission and should only be used for the 4.6L but if you don't believe me put one behind a 5.4L and blow it up in 30 days. The other transmission the one I will be using is a ZF5 S5-47M (the "M" is for modular engine the 5.4L and 6.8L have same bell housing) the transmission is a direct bolt up to the engine and all you need is the transmission and a new fly wheel and drive shafts for sure and depending on the transfer case (I have a 4406-10 the evil ESOF which I will be killing for a manual linkage) and transmission that were in there you may have to change the cross member I think a cross member from a donor truck will work but I'm not sure so I will give a detailed write up of how to change pedals and install a boot for now and add later!

 

[TactialMonkey]

should of taken a pic of the inner liner on the boot but its just a rubber coated plate with a hole in it that goes under the carpet that the internal boot screws on to... don't hate on my cutting the carpet I was curious gorge with a pocket knife hahahaha

 

[FordandPolaris]

Why get rid of the ESOF? That feature is the best part of the 4x4.

EDIT: Unless you are getting rid of it due to the lack of a 2WD option on those model years. Still Brown Wire Mod would fix that much easier.

 

[TactialMonkey]

The manual linkage on the 4406 is just so much more smooth and my esof is moody so I'm not keeping a knob when I can just reach down and move a lever hahaha

 

[spolcyn]

I too put the zf 5 speed in my 01 expe 3 years ago. It was fairly straightforward. I used the original crossmember and just made a plate to connect to. As far as the driveshafts go I had a local shop shorten and lengthen the originals.

 

[TactialMonkey]

how is your mpg on it? and could you post some pictures of how it looks too? and I need to know what the top part that the shift lever connects to like the shift fork housing I cant find those for the life of me

 

[spolcyn]

Well I am not sure about the MPG because the one flaw with my conversion is no speed sensor. The expe had it in the output shaft of the trans, the super duty had it in the transfer case or rearend. Therefore I have not had a speedo for about three years. It is slightly better than it was with the auto, I think. I will spend some time figuring out how to upload some pics over the weekend.

 

[TactialMonkey]

right on thanks man!

 

[spolcyn]

The shifter question I do not understand. The zf I bought came complete with the shifter. If I recall correctly the shifter itself bolted to a stub shaft that was part of the shift fork/top cover of the transmission. I also used the complete slave/master/reservoir/line set from the super duty. The rod which goes from the clutch pedal to master is from a f150 because the super duty rod was too short.

 

[spolcyn]

One more thing you need to budget for is a body lift. I do not think the zf will fit without one. I am not a fan of body lifts, but the bright side is that the 315/75/16's look pretty good on the expe.