Crewcab Project

catbird7

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Some of this is simply mocked up, and will be removed prior to setting engine. Just checking out the colors.
 

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catbird7

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Hopefully it's a long long time before this scene is repeated. She's finally back between the fenders!
 

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catbird7

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Working on transmissions this weekend. Crewcab had auto hubs while the plow truck had manual. Since all of the wiring has been swapped out from the plow truck i need to convert the zf 6 spd to manual 4 x 4 floor shift.
 

catbird7

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Both trans are zf6 spd and both originally connected to 7.3 strokes. One has manual shift 4x4, the other is push button. Unfortunately the manually shifted trans had issues ( popped out of gear) so I'm forced to use the zf with push button t-case however since all of the wiring is from the manual shifted truck, I figured to simply swap transfer cases and mount the shifter. This is where the snowball started rolling down hill. First problem occurred when I attempted to bolt the manual shifter to trans housing. Since those particular threaded holes were never used on the push button trans they were corroded. While tightening those bolts, I snapped off the threaded "boss" (first pic). Since I have the other zf6 spd, I decided to remove both transfer cases and then remove both center spacer castings and simply swap the unbroken case. After all of this work I discovered while these trans are both zf6 spds they are different internally. Push button trans has larger diameter components inside therefore the housings are different and not interchangeable. Also they have different spline count. Manual has 24 spline, push button has 34. Conclusion I need to repair the broken boss and convert the push button transfer case to manual shift. Fortunately the break on the boss didn't extend to the bottom of the threaded hole. There's probably 1/2" of threaded hole remaining. Going to install a threaded stud and epoxy the pieces back in place. Since this boss only supports the manual shifter and it's only one of the two bolts attaching the shifter, hoping it works without issue. The last part of this will be converting the push button transfer case to manual. Just an FYI, after researching I have an NV271 from 2000 which has 24 spline output the other is an NV273 from 2003 and it has 34 spline.
 

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catbird7

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Next I needed to convert the NV 273 to manual shift which was really easy. Simply remove the electric shift motor \ gear reduction unit from the transfer case and open up the case. Remove the center gear. Now weld a 9/16" (wrench size) bolt to the sector gear and reassemble the case. Done! It's that easy. It's also completely reversible if you ever decide to use the transfer case as a push button again simply buy a new shift motor.
 

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catbird7

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More pics.
 

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catbird7

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Another load of motorcraft parts. Replaced all of the lines on the hydro boost + two new trans cooler lines. The other photo is new v-band clamps for the turbo. Planning to hookup batteries this weekend and finally have an opportunity to check some of the work I've done over the last two years. Assuming all of the wiring works out going to attempting firing it up. Everything I read says these engines take a lot of cranking when heads have been replaced.
 

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catbird7

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Thanks! This is the second winter I've worked on it. Swapped all of the wiring, complete dash swap, and engine. No way to test anything until now and so far zero problems. Had one little hicup when first attempting to start engine. Cranked and charged, cranked and charged until finally saying, something isn't right. Gave it a little shot of either and it fired right up but only ran till the either was burned, so I knew it was a fuel delivery issue. Checked filter and no fuel in filter, checked pump and no power to pump. Checked fuses (good), checked & replaced relay, still no power at pump. Further investigation I discovered it has a roll over safety switch designed to cut power to pump in the vent of roll over. This switch is located on passenger side near kick panel and it has a red "reset" button on the top. Sure enough, it was tripped. Pressed the button and now it has power to the pump and fired right up. Still plenty of work to complete the project however this was a huge hurdle. The rest should be somewhat easy in comparison.
 

catbird7

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Now it was time to connect the remaining crewcab harness to the single cab harness. Single cab obviously did not have rear doors or the circuit for rear power windows therefore it was necessary to create a new circuit. Also the crewcab has duel dome lights and powerseats single did not. Long weekend soldering, but it's done. On to the sound proofing materials.
 

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catbird7

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8-Rolls of Peel & Seal later....... Also dropped off seats at upholstery shop. Changing seat color from grey leather to black. Also bought new black carpet.
 

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catbird7

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New carpet from these guys, nice company, nice product. Now if it just had all 40 holes in it! Surprised me, I actually counted and there's 40 freaking bolt holes!
 

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catbird7

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Peeled all of the jute / padding from the original carpet and glued it down first before installing new carpet. Noticed a manufacturing label on the backside which was super ironic. This truck was built in Canada, it was sold "new" from a Ford dealership in Shelbyville TN, and the carpet was made right here in my home town in central PA!
 

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catbird7

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Front sheet metal installed. Still waiting on the seats from upholstery shop. Also installing front leveling kit and doing 19.5 wheel swap.
 

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