tranny swap problems in the 6.9

[shafermartinez]

so i just got done putting a ZF five speed tranny out of a 95 powerstroke in my 85 6.9 and the only problem is the starter the cone on the starter hits the bell housing so a found a starter out of a 7.3 and the shaft is too short to hit the fly wheel.... any ideas??

 

[franklin2]

Did you use the 6.9 flywheel or a 7.3 flywheel? I see once in awhile where someone wants to make their own SMF conversion on a later model truck using the old 6.9 flywheel, but I keep saying to myself "why do they sell a special flywheel to go with the SMF conversion kits?" Maybe you have found out why?

 

[Black dawg]

I think the nippendenso for the 6.9-7.3 doesnt have the cone.

 

[shafermartinez]

i put a 7.3 flywheel and clutch in

 

[94turboidi]

Are you trying to put a powerstroke starter in or is it for an idi? I don't know alot about the other starters but I believe the powerstroke one doesn't fit ours.

 

[Goofyexponent]

When I did my swap, I didn't even unbolt the starter from the bellhousing adapter.

When you say the nosecone is hitting the bellhousing, where is it hitting? The starter bolt boss? Die grind it out a little and be done with it.

Ask BigRigTech about how he made his ZF work on his 6.9. I remember a little grinding to make the starter work.

 

[shafermartinez]

is it going to hurt anything grinding it down? and it is hitting the tip of the cone i think

 

[franklin2]

In the other forum you said you used a powerstroke flywheel on the 6.9. Others here will know for sure, but I don't think that fits the early diesels does it?

From the other forum;

All IDI (6.9 and pre-PSD 7.3) engines use the same starter, whether the truck came with a 4-spd or a ZF5 or a C6 or an E4OD. Those starters are also a royal pain in the posterior to line up correctly, so much in fact that some people get so aggravated that they leave one of the bolts off and run them with just two bolts. I think your starter is just not lining up properly with the flywheel... what flywheel are you using?

Answer;

a flywheel from a 95 powerstroke i believe its like the cone on the starter is hitting the bell housing on the tranny

 

[Goofyexponent]

I was under the understanding that a PSD flywheel wouldn't fit our engines.

The part numbers don't match when crossing them on Rock Auto. Are you sure the flywheel came from a PSD and not a 1994 Turbo IDI?

 

[shafermartinez]

ya sorry the flywheel is from 1994

 

[Goofyexponent]

ya sorry the flywheel is from 1994

...that's ok...S*** happens man, The 1994 was the LAST year for the IDI.

I am willing to bet that the starter cone is hitting less than 1/4" before it goes all the way into place, am I right?

To see where it is hitting, put some high vicible paint on the nosecone, install it, remove it and see if you can grind a LITTLE at a time from the place it is hitting...I am willing to bet it was like BigRig's truck and it's the starter bolt boss.

 

[shafermartinez]

hey thanks for all of your help to fix it i ended up making my own shims to put around the starter and it works great and the five speed is amazing. nothing like finally driving the old 6.9 down the freeway going 90 and listening to the ats whistle. lol