hey everyone i was at work today and i was tearing down a 96 F 350 Powerstroke diesel truck....the motor has been ran with liquid glass in it instead of oil so the motor and nice garrett turbo are seized... but it has a 5spd and transfer case in it wich i want everything off it to put it into my 86 F 250 6.9 my question is will it work? will it bolt up to my motor? ive been wanting to swap the trans for a while because i hate the 3spd auto and want a manual. thanks to all that reply

 

I asked the same thing so look back a few threads here and you'll find everything they told me. The thread is titled T-19 to ZF 5 swap

 

Essentially it's the same swap but since you are starting with an auto there will be a few differences. Grab all the hydraulics from the truck as they can be used on your older truck. You will need to get a pedal cage assembly from an 84-86 ford truck with a manual transmission that used a hydro clutch system. The cages are contoured to fit the dash so it has to come from a truck with your dash style. You will have to drill the holes for the clutch master cylinder to mount to, but the firewall is dimpled so it will be easy to do. I used a 1.5" holesaw for the large hole but had to dremel it just a bit for final fitment. You will need an IDI clutch set as the PSD flywheel wont bolt to an IDI motor. You would be better off to use your old t-case as well as the new one wont have any provision for your speedometer cable. Read the other thread as well and you should be set.

 

alright thanks guys

---AutoMerged DoublePost---

also does anyone know if a banks intercooler off a first gen dodge cummins could be made to fit on my 6.9?

 

with a plasma cutter, grinder, and welder you can make anything fit. it's all about how much work you want to do to make it happen.

 

sycostang....do i need the clutch master cylinder off the PSD or the idi? i have the one off the psd but i notice next to my brake master cylinder there are two holes that are dimpled but the are to close together to be for the clutch cylinder.....

 

You can make the CMC from the PSD work. The only difference between the PSD version and the one that would be on your truck is the angle of the mounting bolt holes. I cant remember which is which, but one has the mounting bolts level/horizontal to each other and the other one has mounting bolts that are slightly offset from each other. If you were to buy a new CMC, the mounting plate swivels to accomodate either setup. As long as you get the big hole in the right spot, you cant really go wrong.

While you are doing this, I would reccommend getting a firewall reinforcement plate. They can usually be had from a ford dealership for about $15. It will attach to the firewall with the mounting bolts of the CMC and help prevent the firewall from tearing as is common on these trucks. There are 2 versions, a big one which is well over $100 and the small one which I mentioned. The small one is all you need as the big version is for trucks that have already damaged the firewall.

 

alright i will do that, I'm assuming i'm going to need to buy the SMF conversion kit for the clutch? The PSD CMC is the one that is offset. I'm going to put the pedals in after i get done putting my intercooler on and then drill the hole. thanks for all the help man

 

Yeah, SMF is the way to go, I dont think the PSD flywheel works on the IDI anyhow. Good luck.

 

alright i'll try to find one...i get the trans and pedal cage and everything tomorrow so i will be able to get started on it.