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  #1  
Old 07-27-2010, 07:57 PM
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Expedition Transmission Swap

Hey All,
Well I have toasted my second 4r100. I have a 2001 ford expedition with a 5.4 4x4. I want to put a five speed in my truck. I had been under the impression that they did not make a f-150 with a 5.4 5 speed. But during my research I found a 2002 with that configuration. I had been thinking that I would buy a used 5 speed out of an f-250 4x4 with the 5.4. What I need to know is if my transfer case will bolt onto the super duty tailshaft or if I need to start researching using a trans out of a f-150. Any and all information will be appreciated.
Thank you,
Shannon
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  #2  
Old 07-27-2010, 08:16 PM
glc glc is offline
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The only 5 speeds that the F-150 had were manuals. If you keep toasting 4R100's, get a rebuild that's beefed.
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Old 07-27-2010, 08:22 PM
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Thank you GLC I realize that. What I need to know is the difference between a super duty manual shift transfer case and a f-150 manual shift transfer case. Do they have the same bolt pattern and are they interchangable?
Thank you,
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  #4  
Old 07-27-2010, 10:13 PM
glc glc is offline
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The F-150 manual trans will not hold up behind a 5.4. The Super Duty manual won't fit in the Expy tunnel without a body lift or a lot of metal cutting.
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  #5  
Old 07-28-2010, 04:38 PM
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glc,
Are those transmissions really that weak? I would hate to put a body lift on this truck, but I might be open to a little carving on the floor boards. So the question still remains. Will an expedition transfer case bolt onto a super duty transmission? Output shaft spline count, bolt configuration, etc.
thank you,
shannon
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  #6  
Old 07-28-2010, 05:44 PM
glc glc is offline
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I'm afraid I don't have that info, sorry. I'd hate to guess and mislead you. However I do know that a M5OD-R2 is a light duty transmission that doesn't hold up to anything much stronger than a stock 4.6. We have a member (JMC) that put a blown 5.4 into his truck that came with a 4.6 5 speed, and he's now on his 5th tranny. The weak spot is the input shaft. I think he said that when this one goes, it's getting a ZF.
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  #7  
Old 07-28-2010, 09:42 PM
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glc,
Is the ZF the super duty trans? I really appreciate all of the info you shared. I guess I need to think long and hard about what I really want to do.
Thanks again,
Shannon
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  #8  
Old 07-29-2010, 12:23 AM
glc glc is offline
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Yes, the heavy duty manuals in the SD are made by ZF. You would actually need the 6 speed, the 5 speed was never made for the Triton bellhousing.
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  #9  
Old 07-29-2010, 08:36 PM
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"the 5 speed was never made for the Triton bellhousing. "


glc,
Are you sure about that? I have found several for sale. I believe that I read that they were mounted to both 5.4's and in V-10 triton motors (same bolt pattern) in super duties. I did find that the output shafts of the zf5 are 31 splines. I will go tomorrow and count the splines on the first 4r100 I toasted. This is starting to look as if it may be a doable project. The real problem will be explaining to the wife why I had to take out the center console and cut a big hole in the floor.
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  #10  
Old 07-30-2010, 02:22 AM
glc glc is offline
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I'm going by our Transmission Information Page.

Model: ZF5
Type: Five speed heavyduty overdrive
Years: 87-99 F2/3/450/superduty
Engines: 300, 351, 460, 6.9?, 7.3

Model: ZF6
Type: Six speed heavyduty overdrive
Years: 99-06 F-superduty
Engines: 5.4, 6.8, 7.3, 6.0

They are probably 6 speeds - first is a granny. I believe the shift **** has L, 1, 2, 3, 4, and either 5 or OD.
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  #11  
Old 07-30-2010, 02:43 AM
JMC JMC is offline
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glc,

The tranny page is wrong. The 99 to 01 SD had 5 speeds behind the Triton engines, the ZF S5-47M. 02 saw the ZFS6-650 as the standard for the gas engines.

And yes the BW 4406 will bolt up to the Super Duty transmission. The Bolt pattern, Spline count and Shaft diameter are the same.

Last edited by JMC; 07-30-2010 at 03:29 AM.
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  #12  
Old 07-30-2010, 01:02 PM
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JMC,
Thank you for the confirmation. Do you have any idea what the over all length of the zf5 is? I need to find this out so I can figure out drive shaft lenghts etc.
Thank you,
Shannon
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  #13  
Old 07-30-2010, 03:47 PM
JMC JMC is offline
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I had those dimensions a long time ago but I have misplaced them. I would not use them to calculate driveshaft size. I would measure instead. Remove the driveshafts in the current set up and measure flange to flange or flange to output shaft end. Once the new set up is in measure again. The difference is what you add or subtract. Note if the first measurement is bigger then you shorten the shaft. If the first measurement is smaller you lengthen the shaft.
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  #14  
Old 07-30-2010, 08:43 PM
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Quote:
Originally Posted by glc View Post
Yes, the heavy duty manuals in the SD are made by ZF. You would actually need the 6 speed, the 5 speed was never made for the Triton bellhousing.
I had a 2001 F250 V10 with a ZF 5 speed.
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  #15  
Old 07-30-2010, 09:50 PM
glc glc is offline
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Yep, looks like JMC posted the correction.

Thinking about it, being that both ZF's have a granny low, the 6 speed may be a better idea, if it will fit. The 5 speed is pretty wide ratio.
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