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post zf swap notes
my auto started slipping on me, but I was able to locate a 93 IDI parts truck in a pinch and paid $400 for all of the parts needed for the swap (minus the clutch/flywheel kit which was an additional $400). Heres a little insight from what I learned for all of you who are thinking of doing this.
-460 zf is not a direct bolt up. The bellhouse bolt locations need to be modified, and is also slightly different gearing.
-IDI flywheel is not the same bolt pattern as the powerstroke.
-ZF is easier to install with the transfer case and downpipe removed. I was able to do it with a floor jack.
-Remove the floor pan and you can easily access the two top bellhouse bolts.
-The auto and manual floor pan can be interchanged. Or you can just cut a hole in your existing floor pan.
-You can use the e4od transfer case w/ the zf, but will have to lengthen the drive shaft or bolt an adapter between flanges.
-If the cabs are the same length the back half of the rear driveshafts are the same. The front half can be interchanged. This was especially handy considering the rear driveshaft on my donor was all ripped up.
-the bracket that holds the auto shift cable under the steering column needs to be removed in order for the clutch pedal assembly to fit.
-You dont need to switch computers, however your auto computer needs to be in the "park" or "neutral" position. Just remove the position switch from the side of the e4od and make sure its cranked all the way to the right.
-the clutch master and slave are a PAIN to bleed once installed. Bench bleed and secure the slave push arm in the depressed position with some wire then install.
-ZF will be alot louder then the e4od, especially with the solid flywheel conversion. I installed some egg-crate foam between the top of the tranny and the trans tunnel. Very little noise now.
Project Truck: 1990 F350 4x4 Dually Flatbed, 7.3 IDI w/ ATS turbo, ZF-5 Manual, Extended Wheel Base
97 OBS F250 Ext Cab Long Bed 4x4 ZF Swapped, VO conversion, TS 6 Position Chip, E Fuel, 6637 Filter, EBPV delete + PCV Reroute, Diamond Eyes 3" Downpipe