automatic to manual 5spd van swap ??? - Diesel Forum

moosiah · 05-23-2009, 12:42 AM

Hi any body here ever converted a van (e350 , 7.3 ,91 )from a c6 or e4od to a 5spd manual shift ?? I'm helping a buddy w his e150 swap from a 300/6 , 3spd to a 300 td mercedes w 4spd manual box frm a 240d. I can find all the parts at p&p ,a 5spd is about 100$ there are lots of manual shift 300/6 vans in the yards right now ... considering the cost of fixing my e4od would run about 1500$ in parts alone I could swap this over and do it for less than that, in the same or less time.... any body????? ideas ????

moosiah · 05-30-2009, 12:51 PM

I'm amazed that no one has tried this ...... and that no one has any ideas or thoughts about this swap........ a pedal box from a e250 w a manual 3spd and a trans from a f250 zf 5spd.......

Alaskapsdvan · 05-30-2009, 01:46 PM

I am just trying to see that in the mind.
I know that there was an older van on a used car lot awhile back that had 3 on the tree.

But putting that shifter down in the area for the doghouse and then the peddle in an area that already does not have an room....

rednexx · 05-30-2009, 02:14 PM

I did it on my motorhome last fall. I used donor parts from an 89 f350. I used the van pedal assembly and added the clutch pedal to it. I installed the clutch master on the opposite side of the steering column as the f series due to lack of room. Had to make a reinforcing plate for the firewall due to lots of flex.
As for the shifter, it does come up through the end of the doghouse, so it needs to be modified. I just cut a few inches off the doghouse and fibergassed it back up and painted it. There are some pics in my gallery that may give some insight. I can't quite remember all the details, but it really wasn't that difficult to mod the pedal assembly.
Let me know if you want more pics and I can take some for you.
Hope this helps.

moosiah · 06-03-2009, 01:27 PM

the van pedal box w clutch pedal has the clutch master cylinder operated by a rod that runs Down ( not Forward like the PU) from the arm between the steering column and the gas pedal to a vertical master cylinder, bolted to the underside of the floor in that little flat spot there...... I just changed out a worn pedal box in Joe's f350 and then messed w his e150 300/6 = Mercedes 300td w 4spd manual conversion. that's what gave me the idea. there are lots of 300/6 3 spd manual box vans in the picanpul yards around here , my only question is : is the throw of the stock van clutch cyl enough to disengage the 7,3 clutch compleatly ??? I would have to drill a hole in the floor board to install the van master cyl, I would make a plate like the stock mounting point has.
thanks for the pix , they answered some q's I had , like just where would the shift lever come up, and now I know that if I used a 4wd transfer case ,where the lever for that goes. nice job that.

dansk · 06-04-2009, 12:19 AM

Rednexx, what did you do with the computer? How does all that tie in with no inputs? I would love to see more pics if you can.
Dann

moosiah · 06-04-2009, 01:27 PM

Ah,,, the computer..... in a pre powerstroke 7.3 all the computer does is shift the trany,,,, ditch the e4od and you have an all mechanical driveline ....... for a later (94/95?) your stuck, they have a 'pcm' or 'ems' that runs everything under the hood.. vans are mostly the same from '75 to '91 , '92 is the start of the type 4 body style van.... twikfpe......

carringb · 06-04-2009, 01:32 PM

I wonder if an F650 PCM would work in a PSD van? The F650 used a separate controller for the transmission, so the engine PCM was standalone.

moosiah · 06-09-2009, 05:04 PM

a pedal box from a 84+ e150 bolts in to a 91 e350. I'm looking for one now. the tranny is easier to find . I see a lot of trucks w the trannys pulled ,and the transfer cases left behind .... just missed out on a 4x4 f350 front axel and trans .... grrr

**klhansen** · 06-09-2009, 05:28 PM

Quote:

Originally Posted by moosiah

Ah,,, the computer..... in a pre powerstroke 7.3 all the computer does is shift the trany,,,, ditch the e4od and you have an all mechanical driveline ....... for a later (94/95?) your stuck, they have a 'pcm' or 'ems' that runs everything under the hood.. vans are mostly the same from '75 to '91 , '92 is the start of the type 4 body style van.... twikfpe......

I know on SuperDutys (99 & up) you can just disconnect the tranny harness. The PCM will just ignore what I can't see/control. I have an auto tranny PCM in my truck (ZF6) and it works just fine.

rednexx · 06-09-2009, 11:52 PM

I'm not sure the early pedal set up would work with the push rod going through the floor. The zf slave has the resivoir on a horizontal, so filling it would be impossible, that's why I went through the firewall.
As for the computer for the trans, I had a C6.
No computers at all to deal with when something quits a 1000 miles from home in a snowstorm or a gravel road!!!

dansk · 06-10-2009, 09:38 PM

I would to hear someone tackling a manual for the later models with good results. It would open up a new ballgame. I would love to have a manual if it could be done.
Dann

moosiah · 06-13-2009, 02:23 AM

as far as I know... I've seen 2 diffrerent pedal boxes , the 84 + is the same until 91 . you could just buy the parts to add the clutch pedal to the newer pedal box , the stamping is the same for both versions the mstr cyl sits vertical and has a remote reservoir, so you fill it from the engine compartment.....
dansk,, look at rednexx pic file .. he did it already

scottyryan · 06-13-2009, 04:40 AM

If someone has done this on a 2003 7.3 - and successfully converted to Manual - I would love to do this....

Anyone have step be step guidance - Or at least a list of required parts and why...

Thanks ahead of time....

van_350sd · 06-14-2009, 02:34 AM

Why would you want a manual?
The 4r100 automatic is a workhorse and works like a dream.