Just picked up 1991 ford F-350 7.3l engine with 5-Speed transmission 2 wheel Drive.

What do I need to put the 5 speed transmission into a 1990 Ford F-250 7.3l with A4OD 4x4?
Got any ideals on this swap. I got to here the Engine run and trans drive before he pulled them and it sounded Great! What do you oil burners think?

I have a list, I guess you'd call it, posted by a member long ago. Never having done the job, all I can do is pass the list along without comment. At least it will point you in the right direction.


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.

Joseph Davis said:

What do I need to put the 5 speed transmission into a 1990 Ford F-250 7.3l with A4OD 4x4?

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I'm confused. Post title says 2wd but your comment says 4wd. The transmissions are not interchangeable unless you have a 2wd transmission with the parking brake bolted to it (because they bolt up in place of the transfer case).

If you put the regular 2wd transmission in a 4wd truck you'll lose 4wd. I've never been in a ZF before but typically converting a 2wd transmission to 4wd requires a complete teardown of the transmission to replace the main shaft and the tail housing.

chillman88 said:

I'm confused. Post title says 2wd but your comment says 4wd. The transmissions are not interchangeable unless you have a 2wd transmission with the parking brake bolted to it (because they bolt up in place of the transfer case).

If you put the regular 2wd transmission in a 4wd truck you'll lose 4wd. I've never been in a ZF before but typically converting a 2wd transmission to 4wd requires a complete teardown of the transmission to replace the main shaft and the tail housing.

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Since this is a F350, chances are that it doesn't have the driveline brake. The other option of doing this is, instead of tearing apart the transmission, you have to find a remote mounted transfer case such as a NP205. Then you have to mount it, build a driveshaft that goes between the trans and transfer case. then you have to make new driveshafts for both the front and the rear. That's not really a wallet friendly option either.
As for the title, it's pretty simple he already has the 1990 F250 with the E4OD. He just bought the 1991 F350 with the ZF5 and is wanting to put it into the F250. Although the wording wasn't the clearest, I had no troubles following the post.

IDIBRONCO said:

Although the wording wasn't the clearest, I had no troubles following the post.

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Nor did I. It was more of a request for clarification that that's really what he meant, and not a typo.

I occasionally have to stop and remind myself that things that are perfectly clear to me come from experience, and as such are things not everyone already knows. I find if I don't, I tend to make an **** of myself and that's something I try to avoid lol.

chillman88 said:

I tend to make an **** of myself and that's something I try to avoid lol.

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I try to avoid it myself.

Thanks for all the info. Too big of job because of all the money you have to through at it. Better stay automatic, and just switch out motors. And sorry for making **** of Myself.

Joseph Davis said:

And sorry for making **** of Myself.

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You certainly did not. I hope it didn't come across as such as that's NOT what I was saying.

The engine will swap right out easy.

If you do get the whole thing, I'm sure you can sell the transmission. Might be lucky enough to get enough to buy a 4x4 version.