Hey guys,
I'm sure this has been covered on here but I haven't been able to find it yet.

Bit of history for those interested:
So I recently bought a new (to me) 2014 Screw ecoboost 4x4 and I decided to rebuild and add a bit more power to my 2001 Screw 4x4 with the 5.4 2v and 4r70w transmission 408k miles and counting. I know there is a lot of hate on this generation trucks but this was my first (and only so far) brand new truck and has never failed me and only been in the shop once due to a gas tank strap recall. Other than recalls, once the warranty ran out I have done all the fluid changes and any needed repairs myself. In 21 years of ownership I have replaced upper and lower ball joints/upper control arms, inner and outer tie rod ends, both front wheel bearings and an alternator. Plus fluid changes as the owners manual specifies. I frequently tow a 26 ft camper and bass boat along with the occasional off road adventure while towing a small pop-up camper. Truck is all stock besides tires. I replaced the tiny 255/70R16s with 285/75R16s. Looks and rides better imo. Speedo is off by around 5 MPH. Old girl is not a pavement princess nor is she pretty to look at for the time being. I already know my transmission is in need of a rebuild (possibly just needs a new torque converter) due to shuddering between shifts. I am retired, like a challenge and enjoy turning wrenches every chance I get.

A friend of mine has offered to give me his 5 speed (minus the transfer case) from his 2002 4.6 truck.

Will my transfer case bolt to the 5 speed transmission or do I need to find a different transfer case?

I already know there are those on here that will tell me to stick with my auto because 5 speed swaps CAN be difficult and the 4.6 transmission wont hold the power of the 5.4. It's not my first rodeo on these swaps, just never with a Ford and if need be the transmission will be beefed up a bit. It's going to be a weekend truck and I really miss shifting gears. If my transfer case will work or I can find a compatible transfer case I'll be having the auto trans programmed out of the ECM when the truck gets tuned.

Thanks in advance for the help guys

 

If the transmissions are the same length and have identical transfer case mounting systems on the tailshafts, they should interchange. You will need a manual transmission flywheel from a 4.6 with the same number of mounting bolts as your flexplate. Some engines were 6 bolt, others were 8 bolt.

When you reprogram, you can correct the speedometer at the same time.

 

AFAIK the 5.4s were 8 bolt flywheels and the 4.6s were either 6 or 8 bolt. I'll have to ask my buddy about his. As far as the transfer case I can't speculate of they bolt the same or not. I'm sure someone here knows for sure it's just a waiting game at this point. As far as overall length I'm 100% ok with having driveshafts made. The great part about being old and personally knowing many people in the machine shop and automotive world is that I have a wealth of affordable skills and manufacturing to call on.

 

The problem with different length transmissions is not just the driveshafts, it's the transfer case mounting to the vehicle. If you have an 8 bolt flexplate, just buy an 8 bolt flywheel for a manual transmission 4.6, those are easy to find, as are clutch parts.

This should not be that difficult a swap.

 

Doing more research, it seem that the auto and 5 speed are the same length. Now the only big question left is whether the transfer case from my auto will bolt up to the 5 speed.

 

Logic would say that the mounting should be the same, but as with anything, that's not a done deal. It would make sense for Ford to use the same transfer case for all F150's but you never know. I do know that on a RWD pickup, the driveshafts are different for manual vs. auto, I don't know what the difference is.

 

I've been poking around online and haven't found any concrete information. It's frustrating that the info I am looking for is so hard to find

 

I just searched at car-part.com, there are 3 different transfer cases listed for a 2001 - XL34-7A195-AB, XL34-7A195-AC (both manual shift cases) and a electronic shift case. Looking through both manual shift cases, I see them listed for both manual and auto trans and all 3 engines, I don't see any electronic cases listed for manual trans.

 

Yeah, I saw the same thing. I guess I'll have to source a transfer case. On a good note, I've received, headers, cams, valves and springs in the last few days so now the real fun begins.

 

I'm actually thinking your case will still work. When the same part number is for both manual and auto, that leads me to believe they are the same.

 

That's my thinking as well but I do have the non manual shift transfer case. I'm not sure what I would have to do if I wanted to get in low range since with the auto I have to be in neutral to go in low range. Also, while doing a bit more reading on this project, I have learned that if my stock crank is forged (50/50 shot as I understand), it will be a 6 bolt crank. 8 bolts for cast. Still currently driving the truck everyday as my 98 Expedition backup truck needs a little TLC before I get started (trailing arm and track bar bushings need replaced and it has a ball join worn out so I'll replace all of those along with tie rod ends). Not looking to be driving the "new" truck a lot till I finish this project as I'll be in and out being covered with oil and back and forth from the junk yards getting a few parts for the project.

 

Both the electronic shift and manual shift transfer cases operate the same way to go into 4lo. Foot on brake, automatic in neutral or clutch depressed with manual. This is a guess, but I'm thinking this is a GEM function.