1997 e4od-zf5 swap, need advice/help - Ford Powerstroke Diesel Forum
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Old 07-01-2013, 03:34 PM
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1997 e4od-zf5 swap, need advice/help

OK, I am trying to round everything up I need to do my zf5 swap. I have the transmission, cross member, clutch, solid flywheel, shifter handle, transfer-case linkage, clutch/brake pedal assembly, steering column, slave cylinder, line, and reservoir... Now, the donor truck is a 1990 f-350 rclb 7.3 zf5 4x4, will (1)the harness for the transmission hook up to the harness on my 97 f250 7.3 4x4 auto? (2) will I need an idm or ecm from a 5 speed truck or will I be ok with the stock ones, (3) Will the neutral safety switch wiring in the 1990 work in my 97? If not what will it take to make it look as if its factory? (3) Does anyone know how much shorter the zf5 is than the e4od, and how long the rear drive shaft will need to be lengthened? I have the front half of a drive shaft from a 1995 f250 2wd 7.3 5 speed that had a 2 piece shaft. it is roughly 3-4 inches longer than the front half of the drive shaft in my ccsb. If anyone has any input on this, I would greatly appreciate it. I just want to make sure I have everything planned out and all the parts ready to just throw at it in one weekend. Thanks in advance guys.
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Old 07-02-2013, 08:10 PM
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you will either need a chip that is set to fool your ecm to thinking its a 5speed ecm or an actual 5sp ECM, the IDM is the same accross all trucks exept the variations in injector signal voltage.

i did this swap few years ago dont remember measurements though. but i do know i found a post on here that said the differences.

i beleive the Neutral Safety Switch or "Clutch switch" is actualy already in the vehicle under the carpet with a factory Bypass wire already in it. i cant fully remember though.

i had also gotten the floor pan out of a donor truck so that way i didnt have to cut the floor. salvage lot let it go for 15$ didnt bother me as i then had to do no measurements for cuts.

your truck will run with the Auto ECM but you will have no cruise control and OD light on shifter will always be on. my truck "96" ran like a champ no limp mode or anything. you need a different harness for the Manual then the Auto also if you want reverse lights and such. the auto harness unplugs from the main harness and a manual's harness plugs right back in if i remember right.

i now have a 96 4DR regular box auto that i will most definately do a zf5 or zf6 swap into ....althought unlike my first ill wait till the auto dies before doing it as i have more then 1 vehicle now.

Last edited by 96strokerlb; 07-02-2013 at 08:26 PM. Reason: i felt like it
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Old 07-02-2013, 08:27 PM
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and while im at it.. the ZF5... HUGE improvement on pulling EGT control over the E4OD
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Old 07-02-2013, 08:59 PM
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Quote:
Originally Posted by 96strokerlb View Post
i beleive the Neutral Safety Switch or "Clutch switch" is actualy already in the vehicle under the carpet with a factory Bypass wire already in it.
The wiring and connector for the clutch switch are there. In the automatic trucks, the connector has a jumper block that permanently closes both the cruise and start circuits. You could leave that block in place, but (1) the cruise won't interrupt when you hit the clutch, and the engine will redline, and (2) you'll be able to start it in gear with the clutch engaged. **SOME** new master cylinders (or complete hydraulic kits, if you choose that route) have the clutch switch included on the pushrod. If you're getting the master off a donor truck, it might have the switch already. In that case, you'd just remove the jumper and plug the connector into the switch, and Bob's your uncle. You'll need a reverse light pigtail to splice into the reverse light wires on the existing connector that used to go to the auto tranny. If the donor truck is junk, you could just cut it off that truck, but they're only a few bucks at RockAuto.

Quote:
your truck will run with the Auto ECM but you will have no cruise control and OD light on shifter will always be on.
...except the shifter won't be there ...

Last edited by madpogue; 07-02-2013 at 09:03 PM.
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Old 07-02-2013, 09:44 PM
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Awesome info. The only thing missing from the donor truck before I got it was the bed. So the wires I will need, being from. '90 "should" work on my 97?
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