My ZF6 Swap!

[Mud-Nut]

After installing a TW chip on my truck, my 4R100 started slipping in 2nd gear. So I decided to go with a ZF6 swap instead of the BTS auto. Unfortunately, I couldn't find a donor truck for the swap, so this makes the swap a little more difficult. Fortunately, Ford made everything pretty straight forward. So far, the only fabrication I'll have to do is the floor hump. I started by accumulating parts.

Here's the most important part:



13" flywheel from Valair





Valair clutch (NMU70241-01)





Here's the rebuilt ZF6 from Joe's Transmission. I recommend giving these guys a call if you need a tranny. They were VERY helpful and got me tons of parts along with the tranny! They threw some stuff in for free and were great. We had some shipping issues, which delayed this swap big time, but that was beyond their control. They apologized and took care of the issue no problem!



New clutch pedal and whatnot....







Truck pulled into the shop, ready for the swap.



Parts and truck.





Yanked the NV271.



Exhaust out of the way.



Working on this 2001 is sooooo nice!! Everything comes apart so easily compared to when I first built my 1979! Haha!



4R100 out of way!





Next step was to strip the interior.







We found a bit of surface rust. It was taken care of and coated with POR15. That should slow down the cancer.



I took a bunch of comparison pics of the 4R100 and ZF6.















Next step is to change the input shaft on the transfer case. To swap the input, you have have to take apart almost the entire transfer case.

[Mud-Nut]

Input shaft for the 4R100 on the left, and the new input shaft for the ZF6 is on the right.



Swapped in.



Transfer case re-assembled.





Same transmission mount is used on both transmissions. The mounts are located slightly different on each, but there's holes for both on the crossmember. It's almost like Ford wanted us to do this swap!!! Haha! So far, this is the easiest project I've taken on in awhile!





Unfortunately, I never found a floor hump. I'll just build up the floor on my own. I'll do that after the tranny is in place next weekend, but I did cut the hole for now.







And that's as far as I got this weekend. I'm really enjoying the swap thus far, and can't wait to get it all done! Here's a few more pics.







The swap continues next weekend, I'll update with many more pics then.

[ScottyP5947]

Amazing, great documentation.

Scott

[jse51599]

I know it's stupid, but I noticed your 666 on the license plate. I'm sure that has nothing to do with any problems you've encountered along the way.....

[ScottyP5947]

I showed it to the wife and said, "man, I want that plate!"

I have 444 in mine now so I guess I'll have to be happy with that!

Scott

[jse51599]

Originally Posted by ScottyP5947

I showed it to the wife and said, "man, I want that plate!"

I have 444 in mine now so I guess I'll have to be happy with that!

Scott

Yeah, mine is pretty plain.

[jse51599]

Well, the 444 is the cubic inches of the 7.3 ya know...

[Cj Ford]

looks good serge ... one of these days ill be swapping a front axle and t case into mine ... still looking to buy a wrecked parts truck

[ScottyP5947]

Yes sir, I got lucky.
To the OP, what made you want to go manual? I'd love it, but...

[Cj Ford]

Originally Posted by ScottyP5947

Yes sir, I got lucky.
To the OP, what made you want to go manual? I'd love it, but...

is there anything else but manual? LOL