2wd Manual trans question - Ford Powerstroke Diesel Forum
 
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post #1 of 8 Old 12-05-2010, 07:51 PM Thread Starter
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2wd Manual trans question

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!

04 F-350 4x4 CC SRW
ARP Studs, EGR Delete, Sinister Coolant Filter, AFE Intake, MBRP Straight Pipe with 6" Black Miter Cut Stacks, SCT X3 with Innovative Tunes, Gauges on the Pillar, Skyjacker 6 inch lift, Beefed up 5r110, 22" XD Badlands with 37" Falken Wildpeak AT's, Warren Diesel 190/75 injectors, Blue Spring with 6.4 Banjo's, and a Boat Load of Little Things... I'm also on the lookout for anything/everything to do a ZF-6 conversion, PM me if your looking to sell
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post #2 of 8 Old 12-06-2010, 02:45 PM Thread Starter
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Anybody with general ZF transmission knowledge??

04 F-350 4x4 CC SRW
ARP Studs, EGR Delete, Sinister Coolant Filter, AFE Intake, MBRP Straight Pipe with 6" Black Miter Cut Stacks, SCT X3 with Innovative Tunes, Gauges on the Pillar, Skyjacker 6 inch lift, Beefed up 5r110, 22" XD Badlands with 37" Falken Wildpeak AT's, Warren Diesel 190/75 injectors, Blue Spring with 6.4 Banjo's, and a Boat Load of Little Things... I'm also on the lookout for anything/everything to do a ZF-6 conversion, PM me if your looking to sell
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post #3 of 8 Old 12-06-2010, 02:51 PM
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Originally Posted by AtomicZebra View Post
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.

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post #4 of 8 Old 12-06-2010, 03:40 PM Thread Starter
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Originally Posted by Abel@KN Filter Specialist View Post
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!!

04 F-350 4x4 CC SRW
ARP Studs, EGR Delete, Sinister Coolant Filter, AFE Intake, MBRP Straight Pipe with 6" Black Miter Cut Stacks, SCT X3 with Innovative Tunes, Gauges on the Pillar, Skyjacker 6 inch lift, Beefed up 5r110, 22" XD Badlands with 37" Falken Wildpeak AT's, Warren Diesel 190/75 injectors, Blue Spring with 6.4 Banjo's, and a Boat Load of Little Things... I'm also on the lookout for anything/everything to do a ZF-6 conversion, PM me if your looking to sell
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post #5 of 8 Old 12-06-2010, 03:48 PM
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I'm gonna assume the bellhousing is way different if its on a 5.4 gasser.

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Originally Posted by alberta 7.3 View Post
Yeah, I'd probably feel a bit drained after firing twice in rapid succession.
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post #6 of 8 Old 12-06-2010, 03:58 PM Thread Starter
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Originally Posted by Jake View Post
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!!

04 F-350 4x4 CC SRW
ARP Studs, EGR Delete, Sinister Coolant Filter, AFE Intake, MBRP Straight Pipe with 6" Black Miter Cut Stacks, SCT X3 with Innovative Tunes, Gauges on the Pillar, Skyjacker 6 inch lift, Beefed up 5r110, 22" XD Badlands with 37" Falken Wildpeak AT's, Warren Diesel 190/75 injectors, Blue Spring with 6.4 Banjo's, and a Boat Load of Little Things... I'm also on the lookout for anything/everything to do a ZF-6 conversion, PM me if your looking to sell
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post #7 of 8 Old 12-06-2010, 04:55 PM
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That is some good info. I wasn't sure but i woulda thought theyd be different. Guess i was wrong. Thats a first lol

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Quote:
Originally Posted by alberta 7.3 View Post
Yeah, I'd probably feel a bit drained after firing twice in rapid succession.
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post #8 of 8 Old 12-07-2010, 02:05 PM
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Quote:
Originally Posted by AtomicZebra View Post
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.

http://www.yorkdaleford.com/service.html

Ford Diesel/Senior/Master Tech who placed 2nd overall in Ontario on the Fix-It-Right-First-Visit score for 2010

....who works at a dealership that now employs SOME half decent looking female employees since they overhauled most of the administrative staff

....but STILL loves hot women with big boobies

....and STILL hates working on E-Series with 6.0L

Last edited by m-chan68; 12-07-2010 at 03:28 PM.
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