Transmission Swap (E40D to ZF5)
 

I've searched the Diesel Bombers forums, and practically the whole internet for a write-up on an Automatic transmission to Manual transmission swap for my truck. I have yet to find a thread where the posts are grammatically sound and comprehensible, or where people know what they're talking about. I'm looking to construct a thread where myself and others can figure out what parts they need to do the swap. I'm mechanically inclined but not enough to where I could figure out what I need on my own. Any and all who have knowledge of such a swap or have done it themselves please contribute below, and I will edit the list of components as needed. Thanks in advance! With any luck this could ultimately be made into a sticky!

*AT = Automatic Transmission
*MT = Manual Transmission



1. Manual transmission (ZF5)

2. Master cylinder and manual transmission pedal assembly

3. Non-AT steering column?

• I've read that you can remove the AT shifter and install a plastic piece in its place?

4. Different driveshafts?

• I've read on various threads that driveshafts from an AT truck will line up?

5. Computer swap / Re-flash?

• Supposedly you can either reflash your current computer or get a computer from a MT truck.

6. Clutch, flywheel and pressure plate.

7. Clutch safety switch

• (For cruise control, and starter interlock.)

8. Slave cylinder w/ line and fork.

9. Pilot bearing and throwout bearing.

10. Bell housing.

11. Cross member from a MT truck?

• Supposedly there are alternate holes pre drilled and you can move your AT crossmember.

12. MT shifter, boot, and molding.

13. 4x4 lever mounting bracket from a MT truck.

14. ZF5 wiring harness.

Info Sources