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Old 01-23-2011, 12:50 AM   #1
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Default Automatic to Manual Transmission

I've got a 1990 F150 5.0L, AOD auto trans, 4x4, long bed, reg cab. I want to convert to manual transmission. Im aware of cost, pedals and column. My question is which manual transmission will make the swap the easiest? If possible. Has anyone done this?
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Old 01-23-2011, 10:15 AM   #2
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m5odr1, or the zf trans with the hydraulic set up.
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Old 01-23-2011, 10:19 AM   #3
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Are you wanting a Manual with Overdrive or a Manual with a Granny Gear?

There are several manual transmissions that will fit the 5.0L engine.
1996 Manual Transmission Code = C for the ZF Close Ratio.
1996 Manual Transmission Code = W for the ZF Wide Ratio.
1996 Manual Transmission Code = M for the Mazda M50D-R2

New Process 435 (NP 435) Compound Low (Granny 1st & Reverse)
Warner T-18A and Warner T19 - Compound Low (Granny 1st & Reverse)

The F-150 ZF 5-speed manual (M5HD - ZF S5-42) is the one you want and
the Mazda (M5OD-R2) manual transmission is the one you do not want.
But some people have no problem with the light-duty Mazda transmission,
it shifts quicker and smother than the heavy-duty ZF.
------------------------------------------------------------------------
The two top holes on the transmission bell-housing and rear of the 5.0L engine
measure 5 1/8" Center to Center. The 4.9L, 5.0L, and 5.8L (351W & 351C) all
measure 5 1/8" Center to Center.

You may want to purchase another F-150 with a 5.0L with a good manual transmission,
because you will need many F-150 parts to complete the swap.

Major parts you will need for the swap:
Manual Transmission with Shifter & Boot.
F-150 Floor Plate with hole for shifter (or cut hole in floor)
Manual transmission Cross-member Mount
Drive-Shaft from the manual truck
Flywheel / Pressure Plate
Pilot Bearing
Brake and Clutch pedals
Clutch Slave Cylinder (mounted on firewall under hood) (Not with Granny T.)
STARTER for a 5.0L manual transmission F-150
Neutral safety switch (May need to be rewired)
The Steering Column from the manual F-150 (or remove the auto shifter)

Note: If you were to buy a manual transmission from behind a 4.9L engine,
do not use the 4.9L flywheel / Pressure Plate on your 5.0L engine.
(The 4.9L is internally balanced and the 5.0L and 5.8L are externally balanced engines)

Also, while you have the transmission out of your truck,
this would be a good time to replace the Rear Main Seal on your engine.
-------------------------------------------------------------------------

ZF is a heavy duty 5 speed manual transmission and has two different ratios.

ZF S5-42 Close Ratio:
1: 4.14
2: 2.37
3: 1.42
4: 1.00
5: 0.77
R: 3.79


ZF S5-47 Wide Ratio:
1: 5.72
2: 2.94
3: 1.61
4: 1.00
5: 0.76
R: 5.24


ZF Lemförder Fahrwerktechnik AG & Co.
KG makes the ZF trans. Heavy equipment manufacturer out of Germany


How to recognize the transmissions:

Mazda = Horizontal and vertical ribs.
ZF5 = Diagonal ribs and PTO cover
[IMG]file:///C:/DOCUME%7E1/Ray/LOCALS%7E1/Temp/msohtml1/01/clip_image001.jpg[/IMG]
-------------------------------------------------------------------------------------------------------
ZF bell housings:
Diesel
429/460, 351M/400
302/351W/ 300/I6

Depending on engine size the ZF had different diameter input shafts
1 1/4" & 1 1/16"
10 Splines
Shafts are different length

One would have to know their stuff to figure out which transmission
they were looking at and if it would fit your engine.
The Windsor ZF had an internal slave cylinder
The Diesel’s starter is on the driver’s side.
If it’s still attached to the engine; you would know…

The ZF-S542 is shorter than the Mazda transmission.

The ZF has a standard fixed yoke and the M50D has a slip yoke.
You may have to go to a machine shop for a custom-length drive shaft.

Motorcraft MERCON automatic transmission is used in the Mazda
& the ZF transmissions as long as it was not behind a diesel engine.


ZF S5 42 = Close ratio
5-speed ZF S5-42 manual transmission:
The S in the ZF S5-42 name is short for synchronized,
the 5 designates the number of forward speeds, and
the 42 stands for the ZF's torque output maximum of 420 lb-ft.


Regardless of what anyone says; a Ford 4.9L Flex-Plate and/or Flywheel should
never
be installed on a V-8 engine because the V-8 will VIBRATE above 1500 RPM.
(The 4.9L is internally balanced and the 5.0L and 5.8L are externally balanced engines)

Good Luck!



Last edited by 1987 F-150 XLT 4x4; 01-23-2011 at 10:30 AM.
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Old 01-23-2011, 12:04 PM   #4
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I'd like to have the over drive. Im aware its going to be a costly swap but to me its worth it. I'll collect the pieces overtime. So which overdrive tranny would be best? And i can find the tranny code on the driver door sticker right?
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Old 01-23-2011, 07:07 PM   #5
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also, these will will work with a transfer case right?
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Old 01-24-2011, 08:02 AM   #6
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Check the Transmission Code on the Door Jamb Data Plate,
but double check the transmission itself in case it was swapped out
years ago. The Code for a 1996 may not be the same Code for a 1987,
you will just have to look at it and ask questions.

If the Manual Transmission is in a 4WD truck, ensure the Transfer Case
is the same as your Transfer Case or you may have to buy both and install
both in your truck.

Do not purchase a 2WD Manual Transmission;
thinking you are going to take the tail-piece off and installing it to your transfer case,
yeah, it can be done if they are compatible, it's just a lot of work and a
transmission specialist should be the one doing it.

Since you have time, look around and get all the correct parts
before you start your Automatic to Manual swap.

The ZF 5-speed transmission is the one you want,
you will need to be looking at F-250's or some 1995-96 F-150's have the ZF also.

The weaker Mazda manual 5-speed transmission comes in most F-150's.

Good Luck!

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Old 01-24-2011, 03:07 PM   #7
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I'm not sure if the 96 has it but my 92 f-150 has a concentric slave that is mounted in the tranny bell
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Old 01-24-2011, 04:32 PM   #8
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Quote:
Originally Posted by Flareside Devil View Post
I'm not sure if the 96 has it but my 92 f-150 has a concentric slave that is mounted in the tranny bell
----------------------------------------------------------------------

Yeah, you're right...

Some F-150 Manual Transmission Trucks have a
External Slave Cylinder and some have a
Internal Concentric Slave Cylinder.

There is a Slave Cylinder Reservoir under the hood on some
1980-up F-150's with a manual transmission.

All I got


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Old 01-24-2011, 04:53 PM   #9
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I know that i have the res on the left side at the firewall and if it is the internal slave then you need make sure that when you take the tube off that you don"t mess up the o ring or get dirt in the tube. when you go to reinstall the tube you will need to bleed the concentric slave as I've learned don't miss this step
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