Power Strokes 1994-1997 Upgrades and AftermarketUpgrading or adding OEM or aftermarket equipment to your 1994-1997 Ford F-Series with Power Stroke engine.
The truck in my signature was an automatic used for towing a 38’ 5th wheel.
I was disappointed with the performance of the E40D while towing the 5th wheel and convinced myself the truck would perform better with a manual transmission.
In 2008 I bought a wrecked 97CC 4x4 that had a ZF5 and decided to swap out the E40D in my truck. Though it was missing the motor, the donor truck had everything else (wiring harness, PCM, pedal cluster, steering column, etc) to do the conversion the right way.
Because I hate leaving anything to chance, the ZF5 was rebuilt and everything else that was considered a wear item was replaced.
The transmission was rebuilt in Spring of 2009 and sat in my garage (filled with oil) until I installed it in my truck during Summer of 2011.
I really like driving with the manual transmission when the truck is unloaded or just slightly loaded. With the 5th wheel attached it’s a whole different picture. I feel there is to wide a ratio between 1st & 2nd gears making it hard to get the trailer rolling (especially on hills) without a lot of jerking between shifts.
Some could say the problem is that I don’t know how to drive a stick shift……fair enough . Having owned nothing but manual transmission cars & pickups in the past, I feel I’ve given this setup a fair trial and have decided to convert back to the E40D. I’ve made an appointment in mid-January to have a BTS transmission built for the truck.
If you are interested in converting your OBS truck from an auto to a manual, I have all the parts necessary to do the job. Look at my posting in the “For Sale” section titled “All Parts Needed for E40D to ZF5 Conversion”.
The ZF5 transmission is still in my truck. I’m hoping to find someone within driving distance who will be interested in the parts and can come out to drive the truck so they know exactly what they are getting. This truck is not my daily driver, therefore it’s only accumulated 6200 miles since the conversion.
If you live near the Portland, OR area and are interested in this setup, I would be happy to let you test drive and go over all the details of the conversion.
Daily Driver:Dark Blue 2000 Jetta TDI w/5 Speed. Consistent 49MPG in mix driving. 298,000. Converted to run on WVO in April 2004 with 190K since WVO conversion.
I really like driving with the manual transmission when the truck is unloaded or just slightly loaded. With the 5th wheel attached it’s a whole different picture. I feel there is to wide a ratio between 1st & 2nd gears making it hard to get the trailer rolling (especially on hills) without a lot of jerking between shifts.
FWIW, my 94.5 originally came with 4.10's and the 542 ZF5. I was not too happy with 1st & 2nd when I swapped to a later 547 trans. The higher ratio gears did not mix well with 4.10, much better suited to a 3.55, which I've since switched to.
With that said I reluctantly have to agree towing heavier loads (7k in my case) with the handshaker takes some patience.
I've towed fairly heavy a couple times with my truck. Heaviest was over 17,000# gross, truck, trailer, & cargo in truck & on trailer. Even with 3.55 gears I was impressed with the way my stock truck performed. No jerking, lurching, etc. I could idle around in 1st gear at a crawl and on the road I could idle away from a stop in 2nd gear. But then I've driven everything from single axle dump trucks to 18-wheelers for somewhere between 2 and 3 million miles so I'm used to running up through the gears when heavily loaded.
With your 4.10 axles I'd sure stick with the ZF, but it's your truck, so your choice.
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Denny
'96 F-250 Reg. Cab 4X4 5-sp POWERSTROKE
298,500 mi & NO Problems, LUK Clutch
With your 4.10 axles I'd sure stick with the ZF, but it's your truck, so your choice.
I see your point and thought long and hard about the decision to go back to the E40D....especially since it took me a while to convert the truck over to the ZF5. The only reason I'm going back to the E40D is the good stuff I'm hearing about the BTS transmission. If that weren't an option, then I'd keep the ZF5.
I sure am going to miss how slow the ZF5 can go in reverse while in 4-Low. It is so easy to back the trailer. Just let the clutch out completely and creep backwards into place.....no throttle necessary.
Daily Driver:Dark Blue 2000 Jetta TDI w/5 Speed. Consistent 49MPG in mix driving. 298,000. Converted to run on WVO in April 2004 with 190K since WVO conversion.
Daily Driver:Dark Blue 2000 Jetta TDI w/5 Speed. Consistent 49MPG in mix driving. 298,000. Converted to run on WVO in April 2004 with 190K since WVO conversion.
You will love the BTS tranny. I have had mine in for 300k miles most of the time pulling a 24' cargo trailer coast to coast. The trailer is 4500# empty and with the cargo I was hauling another 4500#. I could pull at 75mph with the cruise control on. A BTS tranny does not drive like a stock one. Brian and his wife Patti are great to deal with.
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95 350 CC SRW 4X4.486K. Amsoil everwhere w/dualbypass filter. Early Centurion model custom paint (white with grey striping) Grey shell, brushguard, Flexsteel leatherseating wood trim and overhead console. BTS hold on tight E4OD tranny. Custom chip by Cale Thompson at BTS. Hypermax DP. Tymar Open element intake. Tru-Cool 28,000 GVW trans cooler plus Super Duty trans cooler. Super Duty Intercooler with GTS pipes. CCV mod. 3 pod A pillar guages with Isspro Pyrometer,Boost and Tranny temp guages. Fumoto oil drain. John Deere coolant eye. Sylvania Ultra Silverstars. Joe Servo IDM. BABY SWAMPS. Magnaflow 4" exhaust. Tymar Coolant Filter. Sirius satellite radio. Kelderman Air Ride on the rear. Autolights clear diamond headlights. Mods as the budget will allow.I think I am almost finished.
A BTS tranny does not drive like a stock one. Brian and his wife Patti are great to deal with.
I rarely tow anything heavy yet but am thinking about a cooler and a valve body from BTS soon as the 1-2 shift is lazy and the 2-3 shift is randomly abrupt. I've addressed all of the usual suspects. Later maybe a torque converter when we get a camper or 5th wheel. For a stock truck (a down pipe in the near future) how does the BTS not drive like a stock one loaded, and unloaded?
Many thanks!
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'96 F250, PSD, crew cab/short bed OBS, auto, 4x4, bone stock
I've done both conversions myself. Just went ZF5 to BTS auto a few months ago! Only problem i ran into was the connector pin out on the firewall was different from the 95 to 97 truck. I ended up changing every harness on the truck other than the one on the motor! Had to replace harnesses in the Dash, under hood and under truck! It was a job!!! You'll love the BTS!
Jake
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1995 F-250 STROKE. 5 speed to BTS auto conversion "done right",DUALLY conversion, 4 inch stacks. IDM mod, Tymar cold air intake,Down pipe,6 pos flip chip, 189,000 and going strong! And the best part, ITS PAID FOR!!!!!!!!!!!!!!!!
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. Having owned nothing but manual transmission cars & pickups in the past, I feel I’ve given this setup a fair trial and have decided to convert back to the E40D. I’ve made an appointment in mid-January to have a BTS transmission built for the truck.
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