ZF5 Swap

[mightykp]

1995 2wd Dually 4-door
Just did an engine swap and the e40d is throwing fits and leaking.
Engine is strong (and came with the zf5) so now going to jump in.
While the transmissions are out, change rear main seal even though seems pretty dry? Seems the seals come with a repair sleeve. Good idea or reasons not to? Anything else while semi-open?
Also, anybody know the thread for the bolt holding shifter to tranny?
Drain zf5 before and fill after install unless reason not to?
Daughter had a 91 idi and she loved the 5 speed after new clutch and smf, so not unfamiliar with them.
Thanks in advance for your help...

 

[mightykp]

Swap Mistake List:
that darn spacer. Didn't realize it comes Completely Off! Wrestling with flywheel for a while and gave up. A few pitcher later, Eureka moment. Pulled it and Flywheel goes on. Here are my pics of it

 

[mightykp]

More Mistakes:
Tight fit issues...
E340D Came off without much of a fight.
Turbo downpipe allowed the passenger middle bolt to loosen all the way but couldn't remove it until transmission dropped. No problem, right... just remember to put said bolt in ZF5 while lifting into place.
Herein lies problem...
ZF-5 Would not install with or without bolt. Not Even CLOSE. Any angle or movement or multiple helpers. Had to Cut Downpipe and remove.
After cutting downpipe (about a foot above the angle taking it to the rear) ZF-5 became...
ZF 5 minute install.
Need to find (I think?) a 3" slip pipe and clamps to re-install the turbo downpipe.
Now f the non oem clutch pedal works...

 

[miked]

I did a e4od to zf5 swap this past winter.

I do not know if you have the correct cross member but I had an issue with drive shaft angles when I made do with a trany cross member that was the incorrect one.

Here is my thread from back then .

drive line angle

Hello I am converting from e4od to zf5 in my 1994 f250 idit short story. I have a 1990 cross member from a 1990 zf5 which would have been perfect but is rusted too badly to use. Found an L shaped cross member in my parts stash which matched the frame bolt face to tranny mount bolt face off set...

www.oilburners.net

Hopefully you have the correct cross member.
Cheers

 

[mightykp]

Thought the crossmember from a 1994 f450 would work. It doesn't. I have one from a 91 IDI and it is different.
Anyone know if the 1995 powerstroke crossmember is specific to year(s)?
Also, the IDI has a counterweight near the tranny mount?