4x4 Conversion - Hole for Transfer Case Shifter?

[bulletpruf]

1987 F350 6.9 (now 7.3 IDI-T), ZF5. Originally 2WD, but has a 4x4 ZF5 and swapping in the 1356 (manual shift) next weekend.

Any ideas on where to cut the hole for the transfer case shifter? I'd rather not just torch a hole in the general vicinity.

Thanks

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[Rdnck84_03]

I did that conversation years ago in an 84 f150 but I had the '89 I pulled the zf5 and 1356 out of. I still have what's left of that '89, I will see if I can shuffle enough crap around in it to get you some measurements.

James

 

[Va_Mike]

Here is a picture from a 1993 that was a ZF5 and 4x4. I assume it had the same transfer case. I can get dimensions for you tomorrow.

 

[IDIBRONCO]

Instead of cutting, you can just swap out the cover plate with the correct one for a 4X4.

 

[Rdnck84_03]

Instead of cutting, you can just swap out the cover plate with the correct one for a 4X4.

The brick and aero trucks have the 4x4 shifter hole below the top plate on the side of trans hump

 

[Rdnck84_03]

I couldn't get any pictures from the '89 as I never pulled the 4x4 shifter after I wrecked it. Ignore the nose, my dog had to investigate what I was doing.

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These are from the hack job where I cut the hole in the '84. The hole along the top edge of tape measure is the first hole from the back.

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This is a half ass picture of the size I made the hole. Never had any issues with shifter clearance.

James

 

[david85]

I never recorded any measurements but here's a photo of the hole I made for my conversion. Note that this is a 1986 style truck with the newer 87-up shift linkage. I rather like the setup because I can pop the shifter into 4H with a nudge from my boot. Couldn't have done that with a period correct 80-86 style transfer case linkage. The shift boot is also the same going right up to the last of the manual shift superduty trucks, so you can still get new ones. Hopefully you can get a general idea by going off the stamped features in the floor.

 

[bulletpruf]

Here is a picture from a 1993 that was a ZF5 and 4x4. I assume it had the same transfer case. I can get dimensions for you tomorrow.

Thanks, @Va_Mike - if you could get dimensions, that would be excellent!

 

[bulletpruf]

I couldn't get any pictures from the '89 as I never pulled the 4x4 shifter after I wrecked it. Ignore the nose, my dog had to investigate what I was doing.

These are from the hack job where I cut the hole in the '84. The hole along the top edge of tape measure is the first hole from the back.
This is a half ass picture of the size I made the hole. Never had any issues with shifter clearance.

James

Thanks for the info - love the pic of your dog peeking through the floor!!!

 

[bulletpruf]

I never recorded any measurements but here's a photo of the hole I made for my conversion. Note that this is a 1986 style truck with the newer 87-up shift linkage. I rather like the setup because I can pop the shifter into 4H with a nudge from my boot. Couldn't have done that with a period correct 80-86 style transfer case linkage. The shift boot is also the same going right up to the last of the manual shift superduty trucks, so you can still get new ones. Hopefully you can get a general idea by going off the stamped features in the floor.

Thanks for the pics. Good to know on the shift boot, too. I'll need to source one soon.

 

[Rdnck84_03]

Thanks for the info - love the pic of your dog peeking through the floor!!!

She can't ever be more than a few feet away from anything I'm doing.

James

 

[Va_Mike]

I haven't made it back over to my parts truck as I had planned. But I should be able to get to it tomorrow or the next day and I will get some measurements and pictures of the transfer case opening. Just didn't want you to think I forgot.

 

[bulletpruf]

Got it done today.

Started by drilling a hole from underneath to mark the center of the hole that needed to be cut. Then got the shifter mounted and figured out where it needed to be enlarged. Then a few more cuts with the death wheel, followed by a quick wire wheel, flap disk, and some paint. I have a shifter boot on the way; hope to install this weekend.

Transfer case rebuild kit arrived today. Hope to finish the rebuild Friday (took the day off work) and get it installed Saturday. Then I can start working on driveshafts.

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[david85]

Looks about right. You might have to open it up slightly once you put the truck on some uneven terrain. These trucks have massive flex, especially long wheelbase versions.