4r100 to zf 6 speed (s6-650) swap - Ford Powerstroke Diesel Forum
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post #1 of 14 Old 04-11-2010, 07:14 AM Thread Starter
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auto to manual conversion with pics

here is some pics of my auto swap for manual.

pics below

Last edited by bjg8599; 12-21-2010 at 06:12 PM. Reason: too little info
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post #2 of 14 Old 04-13-2010, 01:28 PM Thread Starter
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Originally Posted by bjg8599 View Post
Hello, I recently rebuilt my 4r100 for the third time, this time it only lasted two months!! I will never purchase a 4r100 again! I love my truck and am changing it over to a manual as we speak. I am taking pictures and will post them asap. So far everything has been super simple, not super cheap. my question is about my (new to me) 6 speed. What is the sensor on the top of the trans for? there is only one on the whole thing, I took it out and it has a ball bearing with a spring inside a tube. I think it must be for measuring pressure since it can only be moved by pressure from fluid inside. I have looked at hundreds of pages of info and cant find anything. I understand many of you cant understand why i would do this but again i love my truck but hate the auto trans. As soon as im finished i will post pics.
anyone? it is an eletrical connector with a red end. maybe im wrong about pressure, ive never dealt with these transmissions. any help would be appreciated.
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post #3 of 14 Old 04-15-2010, 04:59 AM Thread Starter
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Originally Posted by bjg8599 View Post
Hello, I recently rebuilt my 4r100 for the third time, this time it only lasted two months!! I will never purchase a 4r100 again! I love my truck and am changing it over to a manual as we speak. I am taking pictures and will post them asap. So far everything has been super simple, not super cheap. my question is about my (new to me) 6 speed. What is the sensor on the top of the trans for? there is only one on the whole thing, I took it out and it has a ball bearing with a spring inside a tube. I think it must be for measuring pressure since it can only be moved by pressure from fluid inside. I have looked at hundreds of pages of info and cant find anything. I understand many of you cant understand why i would do this but again i love my truck but hate the auto trans. As soon as im finished i will post pics.
i figured it out. it is a backup light switch! when i switched over to the 6 speed i lost my reverse lights, i wired this switch up to the reverse lights and they work now. the ball bearing must ride up on reverse gear or shaft triggering the switch to turn power on. i will have pics sometime in the next day or two.
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post #4 of 14 Old 04-15-2010, 05:14 AM
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post #5 of 14 Old 04-15-2010, 05:09 PM Thread Starter
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auto to manual swap finished with pics

Quote:
Originally Posted by bjg8599 View Post
Hello, I recently rebuilt my 4r100 for the third time, this time it only lasted two months!! I will never purchase a 4r100 again! I love my truck and am changing it over to a manual as we speak. I am taking pictures and will post them asap. So far everything has been super simple, not super cheap. my question is about my (new to me) 6 speed. What is the sensor on the top of the trans for? there is only one on the whole thing, I took it out and it has a ball bearing with a spring inside a tube. I think it must be for measuring pressure since it can only be moved by pressure from fluid inside. I have looked at hundreds of pages of info and cant find anything. I understand many of you cant understand why i would do this but again i love my truck but hate the auto trans. As soon as im finished i will post pics.
here is the pics! The first pic is the truck before anything except i installed the clutch pedal already, it was very easy everything was already there. the second pic is transfer case input shaft, it was not too hard, if you are trying this swap you already have enough smarts to do it. the third pic is how i cut the floor to accept the new taller s6-650. i then beat with a sledge hammer the rest of the floor up enabling the trans to fit. the fourth pic is the finished product! the fifth pic is the old shift solenoid out of my old auto trans bolted to the side of my frame so the engine started and ran fine and did not throw any codes. i also took all of the other sensors and mounted them to the frame so my computer thinks im setting still in nuetral. i did not cross a single wire using this method. i did however put rtv sealant in all the solenoid holes so that they will function for a long time without being in my old trans.
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Last edited by bjg8599; 04-15-2010 at 05:27 PM. Reason: too little info
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post #6 of 14 Old 04-15-2010, 06:47 PM
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Turned out great! When my truck paid for, I'm going to tackle this project too . How much did you pay for the 6spd?


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post #7 of 14 Old 04-15-2010, 07:09 PM Thread Starter
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Turned out great! When my truck paid for, I'm going to tackle this project too . How much did you pay for the 6spd?
i got it used for 1700 it had 54,000 miles. the clutch pedal assembly was 118. the pre--bleed clutch kit (master and slave) was 210. the clutch kit was 520 at advance auto. the new flywheel was 220 at advance auto. the clutch fork was 28. the new input shaft for transfer case was 220. 7 quarts of atf and rtv sealant 80. new dust shield (2 part) was 84. all parts purchased at ford except for those mentioned. the guy that sold me the trans gave me the shifter column and boot. odd bolts and taps for installing all of the parts mentioned above 14. by the way i found out that all the thread used in these parts are 8 pitch. also ten thousand knuckle breakers and missing skin from my hands but well worth it though. i feel like i have much more power on the ground.
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post #8 of 14 Old 04-16-2010, 06:02 AM
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Quote:
Originally Posted by bjg8599 View Post
i got it used for 1700 it had 54,000 miles. the clutch pedal assembly was 118. the pre--bleed clutch kit (master and slave) was 210. the clutch kit was 520 at advance auto. the new flywheel was 220 at advance auto. the clutch fork was 28. the new input shaft for transfer case was 220. 7 quarts of atf and rtv sealant 80. new dust shield (2 part) was 84. all parts purchased at ford except for those mentioned. the guy that sold me the trans gave me the shifter column and boot. odd bolts and taps for installing all of the parts mentioned above 14. by the way i found out that all the thread used in these parts are 8 pitch. also ten thousand knuckle breakers and missing skin from my hands but well worth it though. i feel like i have much more power on the ground.
Ouch! 3200 bucks! That's cheaper than rebuilding an auto though, and MUCH cooler. I have a few more expenses I guess, since I have the 6.0. They did some goofy crap with an adapter plate on the back of the engine, where the adapter is different from the auto to manual . I think my best option is to buy a wrecked one, and use the parts I needs from it, then part the rest out. All in due time, at least 10 years, because I'm sure that when we have kids, my money will be going to doctors and diapers

So, you bought all the parts from Ford except the tranny and clutch kit? And the tranny hump, you just cut it out, then beat it back with a hammer and siliconed it up? Thanks for your help

I have my dream truck, except the manual, but that can be done


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post #9 of 14 Old 04-16-2010, 06:13 AM
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awesome write up!!!!!!!!!!!!!

so you can tell your passengers that you can decide to drive a manual or a auto depending on what you feel like that day

providing that the auto shifter is still there.

i would just remove the shifter from the column so its not there.

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post #10 of 14 Old 04-16-2010, 06:24 AM Thread Starter
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Originally Posted by 2006PSDSD View Post
Ouch! 3200 bucks! That's cheaper than rebuilding an auto though, and MUCH cooler. I have a few more expenses I guess, since I have the 6.0. They did some goofy crap with an adapter plate on the back of the engine, where the adapter is different from the auto to manual . I think my best option is to buy a wrecked one, and use the parts I needs from it, then part the rest out. All in due time, at least 10 years, because I'm sure that when we have kids, my money will be going to doctors and diapers

So, you bought all the parts from Ford except the tranny and clutch kit? And the tranny hump, you just cut it out, then beat it back with a hammer and siliconed it up? Thanks for your help

I have my dream truck, except the manual, but that can be done
yea, i just cut out the hole and a little more for play room. i then beat the rest up with hammer (about an inch in the middle). i put silicone all over the joints i cut, then taped it with a special metal tape. after that i used the rubber boot to seal around the hole for the shifter so no moisture comes up to the carpet. the bottom of the boot did not fit perfect but so far not a single person has noticed it. i also purchased some thin sound proofing insulation and covered the entire hump area because i read these trannies are loud. it must have worked because i don't hear any noise from tranny. it really wasn't that hard just took some time. everything is already there to bolt up too. the power difference is very noticeable, reverse takes some getting used too since it's opposite from most trucks. i can't believe i didn't do this five years ago, i could have saved several thousand in rebuilt auto's!
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