2wd Manual trans question

[AtomicZebra]

So I have an 04 6.0 and my auto has been giving me trouble lately so I want to swap in a ZF-6. I've done plenty of research and know all that I need to get. So everyday I search for a cheap ZF to get the ball rolling. Today I found a gem that's perfect for me... but there's a problem. Turns out it's only 2wd. The truck is an 01 regular cab dump truck with a 5.4 liter gas motor with a standard transmission (I assume is a ZF-6). The truck is not running due to a stuck starter I guess. He claims 67k on it, looks more like 167k, I'll know when I call tommorow.

So after searching for a little while I think that the 2wd manual has a different output shaft than the 4wd transmission. I know that I have to get a manual transfer case (I wanted one anyways) to make this swap work, but is there some other transfer case that will work... Is it even true that the shafts are different? Any help will be much appreciated since I have to jump on it before it's gone!

[AtomicZebra]

Anybody with general ZF transmission knowledge??

[Abel@KN Filter Specialist]

Originally Posted by AtomicZebra

Anybody with general ZF transmission knowledge??

I know this is an old post but yes the shafts are different. The 2WD output shaft is longer. The 4WD output shaft is shorter.

[AtomicZebra]

Originally Posted by Abel@KN Filter Specialist

I know this is an old post but yes the shafts are different. The 2WD output shaft is longer. The 4WD output shaft is shorter.

Actually I just put this up last night... but if your referring to the question I appologize for asking but I just got tired of searching last night. Would a Ford service manual have a rebuild how to in it?? Thanks for the help!!

[Jake]

I'm gonna assume the bellhousing is way different if its on a 5.4 gasser.

[AtomicZebra]

Originally Posted by Jake

I'm gonna assume the bellhousing is way different if its on a 5.4 gasser.

Well through some research I found out there's only 1 ZF6 which is the ZF S6-650 which was used in 01 and newer Superduty's that were V-10, 5.4l V8, and 6.0l Diesel, all the same bellhousing. Also this is the same tranny in the Chevy 6 speeds with difference's in the shifter I believe for smoother and a quieter transmission, and also to be different than Ford. I thought that the 2wd and 4wd were the same but I guess the shafts are different lengths and the rear housing is different. So I'm hoping it's not too much work to disassemble because this dump truck is one really good deal!!

[Jake]

That is some good info. I wasn't sure but i woulda thought theyd be different. Guess i was wrong. Thats a first lol

[m-chan68]

Originally Posted by AtomicZebra

Well through some research I found out there's only 1 ZF6 which is the ZF S6-650 which was used in 01 and newer Superduty's that were V-10, 5.4l V8, and 6.0l Diesel, all the same bellhousing. Also this is the same tranny in the Chevy 6 speeds with difference's in the shifter I believe for smoother and a quieter transmission, and also to be different than Ford. I thought that the 2wd and 4wd were the same but I guess the shafts are different lengths and the rear housing is different. So I'm hoping it's not too much work to disassemble because this dump truck is one really good deal!!

Think again!!! I hate to be the bearer of bad news, but the bellhousing bolt patterns between the automatic and the manual on a 6.0L are completely different, with 100% certainty. This means such a swap requires changing the rear engine cover, which requires high pressure oil pump cover removal to access as well. The manual versions of the 6.0L and 6.4L have more of a circular pattern to them, while the automatics use a pattern that appear very similar to the pattern used on 4.6L/5.4L and 6.8L engines, but are NOT identical. This is not to mention that the PCMs and the transmission wiring are both completely different as well (The manual version PCMs don't have a TCM integrated and the 3rd connector blanked). That said, you are better off selling your truck and getting yourself a manual truck if that makes you happy. The amount of money and labour you will waste is not worth the hassle.