ZF6 swap 98 Expedition

[SourMashII]

Well.... here it is. Cut and paste of the thread I started on FSB.

It ensues.

^ Should read, it ensues slowly... Have a driveshaft out, adn a chain hooked to tow it to its "hole".. Have taken three Pictures.

Victim/Patient is 1998 Expedition, 140,337 miles. said it would go out at 130-140.. made it 140k...

Traded a wetsand/buff on a ski boat, and two mini details for the '6, and have spent $200 for all the peripherals, new pilot, used pedal, and hydraulics, used clutch, flywheel, etc...

Skiboat that paid for it...











Driveshaft dropped



Mama's chariot, Monstro the Expedition... He gets the shaft ! HAH! (get it, stick shift, shaft, never mind.....)


Console is out, a muthafawka compared to a bricknose Bronco's console.. 40 fasteners... PITA, Royal PITA...

Little apprehensive about effing up the cut for the shifter, the floor is recessed for man shifter, and man t-case... Pretty happy about that, the recess's are there for the cover bolts, as well (the ones that go through the trim)... Looks like a guy could use a 1356 side shifter from a Bricknose or an OBS Bronc/Effy for a mannie shift t-case, but... we will rock it auto shift.. I heart A4WD in the winter, you don't think Monstro just grabs traction.. Makes cookies, and j hooks a real *****.

 

[SourMashII]

Pedal assembly is swapped, dash is rebuilt.

All necessary holes were there, dare I say plug and play?

TC is loose from flexplate, drivesahfts are loose... This thing is over engineered to a fault, and compact. It's like working on a, I don't even know.. One of the things you look forward to on working on a fullsize is access, or room to move... HaySuess! stopped for the night with cross member removed, and 02's disco'd on the side that will need to come out. Exhaust x over pipe runs between trans and t-case... t- case extends past torsion bar mount/adjustment point... Will google, but knne-jerk reaction says the torsion bar mounting needs to come out.

pics later, I took many.



master and hose assemblies.. ^ v



PAy attention to the square hole on the right, master cylinder utilizes that to lock into place... It was kicking my ass, and then I decided to install the pedal assembly and deal with master later.. Pedal assembly was my "missing" link.



AH HA! Eff EWE "PRNDL"!!!!!





see the only difference ^v is the extra hole? Mting area on firewall is there...



you will need to grab one of these little nuts from the donor truck, granted its area is there, but, it is not... basic no wrench required nut hooked to a clasp...



Used to read this....



Now it reads this... snaps right out.. Also too stalk off of the column, and it was stupid easy. That also eliminated the auto locking solenoid for the doors, fail is no PN safety switch....



Hole for the master, there is a ********* there in its place from factory.



getting there....



the holes that this snaps into are already there as well...





Gonna have to get a plug for where the key release goes in the manual...

 

[SourMashII]

All I did today, all day was wrassle the exhaust loose... drop the front driveshaft, etc. Was just gonna cut the exhaust 4 hours ago, wife cried and whimpered, so Father in law came over, and the two of us got these 13 year old rusted together compression fittings loose. Pretty impressive, 140k miles, and the exhaust that Henry and the boys put in place, hasn't been touched....

ALso, a bit of good news, both transmissions appear to be with in milimeters of the same length, and cross member looks dang near plug and play.. Happy about that.

Edit:
T-case is out, and apparently... SPLINE COUNT..... IS WRONG!!!!!!!!!!!!!!!!!!!!!!

Finding a case now... Not plug and play, like in our generation of trucks, my 1993 1356 is bolted to the back of a 1979 F-100 NP435.... , hell it was even a half ton 6 cylinder truck.

SuperDuty has optionally, either a 24 spline t-case... or a 31 spline........or a 34 spline t-case.. I have a 34 spline in my ZF, and a Dodge NV271/3 won't work, as it is a 29 spline count t-case.

Shit, now I need to research how the "hubs" actuate on this rig.... It may end up SAS'd by winter.... If they are vacuum disco, I need to know where that vacuum comes from.









My rear main AFTER 140,275 miles... not a drop of anything, not even seepage.



One of our thoughts along the way, was to drop the $2500 on the Ford ReMan.. Apparently that has already been done, putting Monstro on at least his second E40D in 13 years and 140k miles. We are fourth owners, 1st had for 4 years, 40k miles, second, same third same.. third owner was second owners brother...it was the "perfect" used car in that aspect... Always read bedtime stories and tucked in at night, so to speak. Spent its first 8 years in LA, and then the last 5 in IDaho.





More under car stuff later today.

 

[SourMashII]

half stoned on Clan McGregor, and the body is fully rejecting the new dosage of skatarra... so bear with me.

Umm... THere is a bracket which bolts to the ass of the e40D, it holds both your fuel lines, one is high psi feed, one is return, that will attach to the ZF, you have to drill out the mounting bolt holes to accomodate the slightly larger bolt, and... you can use two bolts to attach it, instead of the one that the slush box utilizes. THe bracket also moves forward to a serviceable position, instead of in an obscure sheerly mental postiion like it was.

Apparently, I think the only hole I will have to make int he tunnel, is for the shifter, that "rise" is my biggest fail. I have jacked and jacked, and re jacked the tranny into the tunnel, for a handful of reasons, not just "forming", and it seems to have self clearanced into position. MAnual mount at this point wn't work, I may be able to flip it, Haven't tried auto mount yet.

X member on these things is a much smarter design than a bricknose/OBS or slant nose bronco. it is "c" channel, that runs up inside the frame rails. Mount bolts come through the frame from the out side of the frame.. It should be simple to relocate, should I have to. Just a matter of drilling new holes, and keeping them straight.

Pics...

Oh, epic fail I had today, was there is an alignment dowel ont he pass side of the block, above the starter.

Apparently, it pulled out fo the donor triton, and didn't pull out of my Triton.I missed that subtlety, and couldn't get tranny to seat the first time. Investigated, adn found I was butting the two dowels together.. ********.... Fixed it, unfortunately I had to drop trans.

the only specialty tool required is a 12 point 12mm for driveshafts.

misc. torx are needed for inside, predominatley used 13mm, 10 mm, 19, 17, and 8. mostly 8,10,13.

Here's the pics, see above caveat about Skatarra knocking me for a loop, out of order, Flickr was being mental, and.. I will describe them to the best of my ability...



Innish ^



I put this in, with the truck, (and bear in mind it sits lower than most, shot airbag suspension, tinier than stock tires... ) sitting on a pair of 15x8 rims in the front, and a pair of 15x6 rims, under the Expy's tires. With a floor jack, some lonely pieces of wood, and a yellow strap.







This is the mounting stud for the above mentioned High PSI fuel line bracket ont he back fo the E40D



If your laptop screen isn't perfectly aligned, you will miss the subtleties.. but this is that bracket, bent tapped and installed to the back of the ZF

 

[SourMashII]

those are my fingers showing clearance, ZF is hanging off 5.4, and that is all, no support other than motor mounts



Money shot of EFI line bracket installed.



the bracket I go on so much about



Back to that bit about the two dowels dueling?



Man that infuriated me.

Here's the little SOB....

 

[SourMashII]

So, I have reinstalled cross member. Trans is on mount on cross member, and I can stuff my fingers between top of ZF and floorboard.

Going to have to re engineer the X member holes, they are 2" shifted to the driver side of where they need to be. Both ZF and E4 mounts are dang near identical, in bolt patterns and overall size, running Monstro's mount as it is in Nicer shape than the ZF's mount.

Starter is hooked, need to cut and swap an end out on the top cooler line, going into the E4, the front line has a 1/4 or 3/8th inch long area w/o threads before the threads start on the coupling. That won't mate into the ZF, so will cut the flared end off the line, and swap them, reflaring and reattaching. the longer or "rear" line from the E4 will be cut down, and then massaged into mating, its fitting does not need to be changed.

Still need to create hole in Floorboard for shifter, and then figure out console solutions... It'll come. Been under the car for 4 days now, it will be a few weeks before I can finish it, its hot, I have other things that need to be done. Probably going to do a tool and nut sweep later, and let it sit for a bit before I handle any of the little details I mentioned in this post. Will punctuate everything I have just typed with pictures later.

 

[KWT2000]

that is awsome... that zf6 will lats forever in an expedition.... they are handling well over 600 horse and 900 ft lbs in the diesels

did you do the pedal pivot upgrade while it was more accesable?

are you going to run a short shifter?

 

[SourMashII]

that is awesome... that zf6 will lats forever in an expedition.... they are handling well over 600 horse and 900 ft lbs in the diesels

Yip

did you do the pedal pivot upgrade while it was more accesable?

Huh?

are you going to run a short shifter?

Haven't decided yet. As I noted in my last post, I am a bit away from finishing, funds ran low... Pesky Mortgage payment anyway... HAve yet to notch for shifter and see where it lays..

She wanted the stick, and the mannie shift t-case, so thinking she wants it as truckish as it can get....

We'll cross those bridges when we get there.

Oh, and as a caveat, if I forget to chronicle it, one will need an OBS/Bricknose Hydraulic hose to communicate the fluid from Master to slave.

Will post pics when I get it done, but hose attachment on F150 master, and hose attachment on ZF slave are same, Hose end where it mates with the Mazduki slave on the F150 master/hose set up is greatly foreign to the ZF.

 

[toms89]

Nice "ski" boat... It might be a bit underpowered to pull a skier at a reasonable velocity...lol. Great job on the finish!!

Thats looks like a pretty big project swapping the tranny. It will be interesting following your install. Good luck!

I swapped an auto into my mustang but thats much easier as no pedals needed to be added and its be done many times before.

 

[KWT2000]

the piviot where the pedal hooks to the master cylinder is known for binding and making it hard to get back into 1st or reverse... they make an upgrade for it that is around $35 it is alot easier to install out of the truck rather than under the dash