'98 Eddie Bauer ZF5 swap

[Bowesmobile]

Quick pic of my final decision on the interior.
A little redneck ingenuity and some help from my GF and the manual trans looks stock!



The only semi tricky part was fabricating a "V" shaped bracket to adjust the shift lever angle. No, I didn't get any pics of that process. Was in the groove and makin' progress. Besides, it's like a movie I and can't give away the plot twist in the end.

This is really cool! Good work man! You are giving me the manual trans itch! If I could find a good used ZF5 or ZF6 that mates to a mod motor for less than 2k. I would be all over it! I would really love to get rid of the auto slush box!

 

[reece146]

+1/Like

Which version of the ZF5 are you using? Wide or close ratio? Do you have the identifier number? Just curious.

 

[Yudaman]

I am using a wide ratio tranny. It came out of a '99 F-350 with a 5.4.
Towed my travel trailer for the first time this morning. LOVE... IT... !!!
Was easy to start out in second gear. No slipping the clutch whatsoever. If I need a little extra grunt, first gear was always sitting there waiting.
As far as ease of installation, the ZF5 is a lot easier than the ZF6. I originally wanted to go with the ZF6, but after all is said and done I think the ZF5 was the better option.
No matter which direction you may choose, the manual is an instant upgrade over the mush box. I am already seeing a consistent 2-3 mpg gain under virtually all driving conditions. I personally love seeing the instant mileage meter showing 20-22 mpg rolling 65mph down the freeway.

 

[IMINYOURCHAIR]

let us know what the actual mpg is by doing a fill up then fill up again to divide miles by gallons used. I don't have the little computer for mpg but I get 16 mpg mixed average on my 4speed auto with the 3.31 rear end.

still want to see what it'll do when you tune the ecu for the 5 speed

 

[Yudaman]

So far, my mileage is sucking. Just can't seem to stop myself from playing. The manual is just too much fun!!! Especially since third gear will go well beyond 70mph. Vrooooom!!!

 

[IMINYOURCHAIR]

sounds fun, my first real experience is behind a 9 speed freightliner cascadia. this thing is mean when i am just bobtailing so I can only imagine the expy when there isn't a torque converter between the engine and wheels.

 

[reece146]

How much does your trailer weigh?

Six speed transmissions are nice to have but a five speed works well obviously. Having two overdrive gears really doesn't get you anything most of the time.

 

[Manlavi95]

Sweet swap! Just a couple questions that are gnawing at me.
1. Where did you get you speed signal
2. Where would you suggest I source parts if I were considering a similar swap?
3. Did you use the factory transfer case?

I see you want to go the 6.8 route, I want to go the 5.4SC route in the end

 

[Yudaman]

Sweet swap! Just a couple questions that are gnawing at me.
1. Where did you get you speed signal
2. Where would you suggest I source parts if I were considering a similar swap?
3. Did you use the factory transfer case?

I see you want to go the 6.8 route, I want to go the 5.4SC route in the end

I used the factory BW4406 transfer case. The speed sensor is off the tailshaft of the t-case, so that made life easy.
Parts were fairly easy to find. Pedal assembly from a wrecking yard, clutch fork and shifter knob from Ford, the rest from Napa or Autozone.

For the guys questioning the difference in the 6 speed versus the 5 speed, they are both good. The 6 speed does not have an extra overdrive. 6th gear is the same ratio as 5th on a ZF5. But the gears in front of 6th have a closer ratio. Meaning not as much ratio gap between gears. 1st gear is also a compound low as well as reverse.

 

[Manlavi95]

I used the factory BW4406 transfer case. The speed sensor is off the tailshaft of the t-case, so that made life easy.
Parts were fairly easy to find. Pedal assembly from a wrecking yard, clutch fork and shifter knob from Ford, the rest from Napa or Autozone.

For the guys questioning the difference in the 6 speed versus the 5 speed, they are both good. The 6 speed does not have an extra overdrive. 6th gear is the same ratio as 5th on a ZF5. But the gears in front of 6th have a closer ratio. Meaning not as much ratio gap between gears. 1st gear is also a compound low as well as reverse.

Thank you very much, now I'm very interested. My 4R100 is starting to make a noise that sounds like sizzling water coming from the pan. Also, is the pedal assembly from an F-250?