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4r100 to zf 6 speed (s6-650) swap

24K views 13 replies 5 participants last post by  Freedombyforce 
#1 · (Edited)
auto to manual conversion with pics

here is some pics of my auto swap for manual.

pics below:)
 
#2 ·
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.
 
#3 ·
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.
 
#5 · (Edited)
auto to manual swap finished with pics

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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#6 ·
Turned out great! When my truck paid for, I'm going to tackle this project too :sly:. How much did you pay for the 6spd?
 
#7 ·
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.
 
#11 ·
i know, it looks funny and even though i know its not hooked up to anything it still feels wierd to not touch it when i park. i plan on removing it this weekend providing i can remove it without to much trouble. with all the trans trouble ive had in the last month im ready to not work on this truck for at least one weekend. i hope this manual is as tough as i've read and will last a long time. seriously, in the last month ive been under this truck more than in it! this swap already has given me so much more confidence in my truck. i no longer have to worry about that dreaded o/d light!
 
#13 ·
everything is still good. I didn't cross any wires, i unplugged all the sensors off of my old auto and attached them to the underside so the computer thinks it still has an auto trans in it. no issues with starter other than the spacer on the 6 is diifferent than on the auto. i had to buy a 6speed spacer. also the starter bolts easily into the 6speed tranny.
 
#14 ·
How about some info on your truck you did the swap in? Especially the year, ESOF or manual t case?\

Thanks.
 
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