94 w/ 96 motor 5 speed manual 4x4 6 speed conversion - Ford Powerstroke Diesel Forum
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post #1 of 4 Old 02-17-2011, 05:02 PM Thread Starter
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94 w/ 96 motor 5 speed manual 4x4 6 speed conversion

My buddy has a really clean 94' with a 96' 7.3 in it thats attached to a 5 speed (yes its 4x4) and we are going to do a clutch in it...well we have both been debating a 6 speed conversion..anyone know what it would take????? is it possible? Does he need a 6 speed and transfercase or will his t case work??? Any input,ideas,write ups, etc would be great!!!!!!!!!!
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post #2 of 4 Old 02-17-2011, 05:24 PM
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6 speed trasmission, 6 Speed clutch and flywheel for 99-03, a 99-03 slave cylinder, You will need a 6 speed transfer case with a 24 spline input shaft. you will need to take the 5 speed trassmission spacer out. 6 speed will not need it. You will have to pound on some sheet metal to make it fit. make your drive shaft shorter and lenghthen you 4x4 shaft. And get a six speed stick. That about covers it
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post #3 of 4 Old 02-17-2011, 10:40 PM
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Originally Posted by Powerstroke Cowboy View Post
6 speed trasmission, 6 Speed clutch and flywheel for 99-03, a 99-03 slave cylinder, You will need a 6 speed transfer case with a 24 spline input shaft. you will need to take the 5 speed trassmission spacer out. 6 speed will not need it. You will have to pound on some sheet metal to make it fit. make your drive shaft shorter and lenghthen you 4x4 shaft. And get a six speed stick. That about covers it
What he said.

Why exactly do you want to go to the six speed? In the end, the total range of gear ratios (1st/grannygear vs overdrive) is nearly the same in the 5 speed vs the 6 speed. I wanted to do a six speed conversion (before I realized how involved it was) when I wanted to drop highway RPMs for fuel savings. In the end however, the 5 speed would basically give me the same gear ratio has the 6 speed in the top gear.

Consider this too: these engines have ample torque to deal with the larger gear ratio jumps in the 5-speed, and larger gear ratio jumps means less clutch use, less clutch use means fewer times that you'll be doing what you're doing now and replacing clutches (which are a bit pricey).
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post #4 of 4 Old 02-18-2011, 05:22 AM
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AT 2000RPMs, 4:10 gearing you will do 60mph with 5 speed, But with the 6 speed in you will do 64mph at 2000RPMs with 4:10 Gears

But if you are lucky and have 3:55 Gears, At 2000RPMs with the 5 speed you will do about 70mph. But with the 6 speed and 3:55 Gears at 2000RPMs you will do about 74mph

You will not wear you clutch out any faster with the 6 speed then you do the 5 speed.
you dont even need 1st (Granny low) for every day driving. just when you tow then the 6 speed will realy shine.
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