I decided to post this because I have read many people saying they wanted to do the same thing
So I finally got it mostly completed. I am overseas now so I don't have pics. I have heard a lot of things over the years some true some not about doing this conversion.
So an overview is in order.
1975-1991 Body style did come with manual transmissions. All of them that I have seen have 300 6 cylinders with floor mounted 4 speeds. I found at least a couple over the years in PIC N PULL junkyards and pulled the pedal box out of one. It is exactly like the auto pedal box except it has a clutch pedal and brake pedal is slightly smaller. An hour or so to remove steering column and then pedal box unbolts. (Note hole in floor next to throttle pedal for rod from hydraulic master cylinder, you will have to drill hole with step drill, easiest to do while your'e pulling steering column out to install pedal box)
Hydraulic master cylinders in vans come up thru floor as previously stated and has a remote reservoir that I mounted on inside drivers fender under hood. Slave cylinder standard ZF5 slave cylinder. I had custom hose built for master cylinder to slave cylinder maybe $20. ( Both ends have 90 degree bends for clearance)
ZF5 Bolts directly up. I used Southbend Single Mass Flywheel and clutch. Hmmm think it was around $350.
With doghouse off you will have to trim rear part of opening maybe an inch for shifter to clear body ( When dog house goes back on it completely covers hole...easy mod. Shifter rod coming out of trans will have to be straightened or stick shift will be facing back towards passenger compartment. It sits fine now, directly where my hand naturally rests when forearm is on Captain chair armrest.
Hole needs to be cut in the rear of dog house. Semi flat part. Using Plastic flange of boot as template. Looks factory when complete.
Obviously Front and Rear Driveshafts need to be adjusted for length. E4OD is much longer than ZF5. MY BG 1356 transfer case bolted directly up ( I obviously used 4x4 ZF5). Note Most Ford transmissions used same bolt pattern so transfer case install fairly easy.
IF you have a turbo on it than your up pipes will need to be modded. Top front of E4OD has more of a slope and ZF5 goes kinda back then drops down so your up pipes may not fit.
Banks and ATS have different pedastals for the turbo mount. Incidentally Justin at R & D IDI has the best turbo mount and cleanest up pipe install. Nice and tight against the back of engine above the trans and tight against heads. Plus JUSTIN is a great guy!
Fairly easy install. I never liked E4OD, didn't like TCM had issues over the years. I like simplicity of manual trans plus you can push start, Bump start if clutch problems arise in the boonies and I usually clutchless shift anyway.
DO IT! I'll Post pics and let you know how it drives didn't get to drive it before I left.
So I finally got it mostly completed. I am overseas now so I don't have pics. I have heard a lot of things over the years some true some not about doing this conversion.
So an overview is in order.
1975-1991 Body style did come with manual transmissions. All of them that I have seen have 300 6 cylinders with floor mounted 4 speeds. I found at least a couple over the years in PIC N PULL junkyards and pulled the pedal box out of one. It is exactly like the auto pedal box except it has a clutch pedal and brake pedal is slightly smaller. An hour or so to remove steering column and then pedal box unbolts. (Note hole in floor next to throttle pedal for rod from hydraulic master cylinder, you will have to drill hole with step drill, easiest to do while your'e pulling steering column out to install pedal box)
Hydraulic master cylinders in vans come up thru floor as previously stated and has a remote reservoir that I mounted on inside drivers fender under hood. Slave cylinder standard ZF5 slave cylinder. I had custom hose built for master cylinder to slave cylinder maybe $20. ( Both ends have 90 degree bends for clearance)
ZF5 Bolts directly up. I used Southbend Single Mass Flywheel and clutch. Hmmm think it was around $350.
With doghouse off you will have to trim rear part of opening maybe an inch for shifter to clear body ( When dog house goes back on it completely covers hole...easy mod. Shifter rod coming out of trans will have to be straightened or stick shift will be facing back towards passenger compartment. It sits fine now, directly where my hand naturally rests when forearm is on Captain chair armrest.
Hole needs to be cut in the rear of dog house. Semi flat part. Using Plastic flange of boot as template. Looks factory when complete.
Obviously Front and Rear Driveshafts need to be adjusted for length. E4OD is much longer than ZF5. MY BG 1356 transfer case bolted directly up ( I obviously used 4x4 ZF5). Note Most Ford transmissions used same bolt pattern so transfer case install fairly easy.
IF you have a turbo on it than your up pipes will need to be modded. Top front of E4OD has more of a slope and ZF5 goes kinda back then drops down so your up pipes may not fit.
Banks and ATS have different pedastals for the turbo mount. Incidentally Justin at R & D IDI has the best turbo mount and cleanest up pipe install. Nice and tight against the back of engine above the trans and tight against heads. Plus JUSTIN is a great guy!
Fairly easy install. I never liked E4OD, didn't like TCM had issues over the years. I like simplicity of manual trans plus you can push start, Bump start if clutch problems arise in the boonies and I usually clutchless shift anyway.
DO IT! I'll Post pics and let you know how it drives didn't get to drive it before I left.
