I have a 2002 f150 with a 5.4 4X4. Right now it has the 4r70w auto with 270,000 Miles on it. I know this trans will not last forever. I am thinking about A ZF swap. I think I will be going to a ZF5 due to having the same spline (31 I think) as my current transfer case. From what I have read the ZF6 has either a 24 or 26 Spline output. and will not work with my current transfer case. I also Have read that the Bell housing for the V10 is the same bolt pattern as the 5.4. My Transfer Case 4x4 Switch Is elect. on the dash.

Parts list:
3" Body lift (Doing it any way)
Pedal ***. Out of a 97-03 F150
Trans
Clutch Pressure plate, trough out bearing, pilot bearing
Clutch master cylinder with hoses
Computer reflashed for Man. trans.


Now my questions are:
-What year and truck do I need to get the Trans out of?
-What do I do about the trans Cross member? New or will the auto one work?
-I know the drive shafts will need lengthen/ shortened, Anyone know how much?
-I am figuring the auto now will cost about $1500 to rebuild is this true?
-what will I need to do for the Speedo?
-Will it run without having the PCM reflashed? (I know I will have Codes CEL)
- Cense it is a Super crew (I don’t think they ever came with Manual trans) will any f150 (97-03) pedal ***. Work?
- what do i do about the stearing colom?

I do not want to go with the 5mod trans, or whatever it is in the 4.6 and 4.2's f150's.
Thanks for any help on this, also if you have any advice on this.

Thanks Mike,

 

https://www.f150online.com/forums/tr...xpedition.html

https://www.f150online.com/forums/tr...sion-swap.html

 

Thanks for those links, the first one is where i got most my info from. But i stil have Most of the questions Posted other than the first. It looks like i need a ZF5 Out of a Gasser 250 From 99-01, Could this please be confermed? Also i would think i would be fine with my Current 40/60 Seat i have in there. Main questions are Cross member, Computer flash, And i think i will need the F250 HYD. cluch system. Also I have a 5" RCX lift if this has anything to do with the cross member

 

Consider having your trans rebuilt by a performance shop such as Level 10.
They can offer you a very near bullet proof 4R70 rebuild that will eliminate all the the hassle and extra expense you will have doing a swap and working out the issues.
That type rebuild is custom heavey duty so it's not going to be in the relm of a stock rebuild, for cost.
My custom rebuild is now 142,000 mile old in a super crew that was used to pull gross weights over 12,000 lbs and really abused for heat and load.
It's one reason why I am holding on to the truck beside a perfect 4.6 motor.
Good luck.

 

Also I think i read where it will, But just to make sure will the Transfer I have now bolted up to the Auto will work with the ZF-S5-47

 

BlueGrass, I have thalt about that, What was the cost for that rebuild, and who will do it? I really think i want a 5 speed though, for the Low first gear, And just to have one. lol
I like to be different

 

I have did some calling around and it looks like the driveshaft ( will be about $200 ) to have them both balanced, or $150 for just the rear ballanced. I will have to shorten the front, and extend the rear.

 

- Cense it is a Super crew (I don’t think they ever came with Manual trans) will any f150 (97-03) pedal ***. Work?

I previously owned an 01 4.2 5spd truck and now have a 99 4.6 5spd truck, as far as I can tell the pedal assembly is the exact same. I'm almost 100% sure its the same on all 97-03 5spd's.

Edit: just re-read your question, I don't know if the pedal assembly is a direct swap for the supercrew.

- what do i do about the stearing colom?

You can remove the shifter and get a steering column cover from a 5spd truck. Patman did this when he converted his truck to center console shift.

https://www.f150online.com/forums/19...shifter-6.html

 

Have you confirmed this? If the zf5 works with the t-case from the 4r70w?
That was one of my concerns for this swap witch i would like to do at some point. I was going to go zf6 since i heard the t-case had to be swapped anyway but if not this may change things.

 

From one of the Links posted above, The ZF S5-47 will from a 99-01 will work, I checked the rear spline and the BW4406 transfer case Takes a 31 Spline Output shaft, and Trans ZF S5-47 Has a 31 Spline Out put shaft, It dont say about the diamater though, but i am sure the guy Said in the exped. He used his stock one with the ZF S5-47. The ZF6 has a 24 Splin output so the tcase will have to be changed on that on for sure.

 

Right now, i am leaning away from the Body lift though, and just cutting the tunnel to make it work, I am not sure witch way i will go on that.

 

Update:
Called a few places to see about questions and prices

-Clutch, Pressure plat, Flywheel-- They are the exact same between the 5.4 and the v10
-Starter, I need on for a f250 with a manual gasser motor.
-Computer reprogrammed, The programmer says with out romoving the auto from the computer it will run, but may go into limp mode.

-Clutch set will be $350
-Flywheel-$120
-Programmer_ $400 ( I dont think i will need this, i will just have some codes from tranny)

I plan on trying to get the flywheel out of the truck the trans comes from, maybe even the clutch set, and starter, just not sure if i want to use a used clutch set, ( we will see)

Also the trans tunnel it more of a squre, (SOmeone did this swap with a 2" BL lift) I think i can get under it with the trans out and kinda round the tunnel so no BL will be needed.

Also call a local pick and pull that has 3 f250's

They have fixed prices on trans and transfer cases.
a Manual trans. is $150, and transfer cases is $125. going to go check it out to see if they are ZF trans. If i find a good ZF6, with a transfer case i will probly do that.

Does anyone know the trans lenths from the bell housing to the Face where the Transfer case mounts to the trans?I am looking for leanths for the ZF5, ZF6, And the 4r70w. I can probly messure my 4r70w, Trying to figure out driveshaft lenths, and cross members locations. The best i can tell mine is about 27.5" for the 4r70w

 

The truck in the links had a 4r100, not a 4r70w, do they use the same transfer case?

 

Everyting i have read say they are, The 99-01 ZF S5-47 has the 31 Spline Output shaft, that is the same as the BW4406 transfer case, Shaft size is the same as well. Form everything i see the BW 4406 transfer case is a direct bolt on unit to the 99-01 ZF S5-47.