Laporterican
Member
I'm about to embark on swapping a ZF5 into my 2003 Navigator. Bought it for cheap with a bad tranny, happen to have a donor 2001 F250 w/ V10 and a ZF5 sitting behind my shop that my wife REALLY wants me to get rid of. Figured I'd save a little money, build a fun daily driver, and give me an excuse to finally get rid of the parts truck (originally bought it for the axles for my 1985 F350 crewcab and interior bits for my 1999 F350).
I would never consider tackling this project without the excellent writeup from Bolt-on
I just happen to have the perfect combination of vehicles to make this fairly straightforward. The Navigator only has 140k, the interior is immaculate, I have full maintenance history, and the body is in extremely good shape for a 20 yr old vehicle, might as well drop a manual in it!
Biggest issues I'll need to tackle:
- Wiring - I'll have to sort through the harness to get my reverse lights , the neutral safety switch, and make sure I can still shift into low range
- Speed Sensor - This will be one of the hardest problems to solve. The 4R100 has a VSS, the ZF5 does not. I'll have to figure out a way to integrate one somewhere along the driveline
- Driveshafts - one will be longer and one will be shorter. I'll need to find a local shop that can do that for me.
- ECU - I'll most likely use 5-Star Tuning to work out any ECU bugs
- Interior - I'd really like to keep the interior looking factory, the shifter will have to be moved back 4-6in. Planning on a short-throw kit to reduce the throw, and fabricating linkage to move the shifter back to where the current console shifter is located.
- Pedal Assembly - According to the previous mentioned thread, the Super Duty pedal assemble will bolt right in with slight modification.
I would never consider tackling this project without the excellent writeup from Bolt-on
6-Speed manual tansmission conversion
I just finished installing a 6-speed on my '03 Expedition (former cop car). I put headers on too while I was in there. The headers were twice the work of the tranny swap. I had to modify Pacesetter 70-2227 headers to clear the frame and drive shaft. Two header bolts were sheared off. The...
www.expeditionforum.com
I just happen to have the perfect combination of vehicles to make this fairly straightforward. The Navigator only has 140k, the interior is immaculate, I have full maintenance history, and the body is in extremely good shape for a 20 yr old vehicle, might as well drop a manual in it!
Biggest issues I'll need to tackle:
- Wiring - I'll have to sort through the harness to get my reverse lights , the neutral safety switch, and make sure I can still shift into low range
- Speed Sensor - This will be one of the hardest problems to solve. The 4R100 has a VSS, the ZF5 does not. I'll have to figure out a way to integrate one somewhere along the driveline
- Driveshafts - one will be longer and one will be shorter. I'll need to find a local shop that can do that for me.
- ECU - I'll most likely use 5-Star Tuning to work out any ECU bugs
- Interior - I'd really like to keep the interior looking factory, the shifter will have to be moved back 4-6in. Planning on a short-throw kit to reduce the throw, and fabricating linkage to move the shifter back to where the current console shifter is located.
- Pedal Assembly - According to the previous mentioned thread, the Super Duty pedal assemble will bolt right in with slight modification.