I'll simply paste in an old posting I lifted somewhere. I have no recollection where it came from or who wrote it. I just copied it and pasted it into a Word document. Is it full and complete? I don't know, but it may add something to your list. I haven't even compared the two.
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Ford parts to swap to 5 speed. This is a parts list to swap from an automatic transmission to a 5 speed manual.
- Ford ZF-5 4x2 Diesel Transmission w/external slave cylinder, non-external brake
- LUK clutch set (dial-a-clutch) comes with flywheel, pressure plate, clutch disk, pilot bushing, release bearing, all hardware and alignment tool
- ZF-5 Trans crossmember w/ lt & rt gussets (there is a difference in crossmembers)
- Clutch master cylinder w/clutch interlock switch (connector under dash, up and right of gas pedal
- Clutch slave cylinder
- Hydraulic line, hard/flex (master cyl to slave cyl)
- Brake and clutch pedal assembly (check bushings for excessive wear)
- Shifter lever (upper)
- Inner dust boot
- Outer dust boot with mount plate
- ZF-5 floor pan
- Clutch release fork
- Spicer HD U - Joints; 3 sets (needed changed)
- U - Joint straps and bolts; 2 sets (needed changed)
- Transmission fluid, 1 gal Castrol TranSynd (warrantee purpose)
- Rear main oil seal (changed because of Murphy's Law)
- Reverse light connector (at trans)
- a good wiring diagram for connecting reverse light and starter relay wiring when using the original E4OD wiring harness
- I used the original powertrain control module (EEC module)
- Also make sure you get every last nut, bolt, screw and washer needed to put it all back together.
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Hope that helps.
