Power Strokes 1994-1997 Upgrades and AftermarketUpgrading or adding OEM or aftermarket equipment to your 1994-1997 Ford F-Series with Power Stroke engine.
Ok, so I got this 96 F350, auto, that I'm putting into a Bronco with a ZF5. The Bronco is lighter than 250/350s, but it's lifted with 1tons, and 40 inch tires, so not sure how that will affect it. Right now I got 4.10 gearing, will put new gears in once I decide on what ratio I want. (any suggestions...I've got good reasons to keep it where it is, and also good reasons to go 5.13s)
First question, is what else will I need to get the PSD to work with the ZF? I know about the clutch stuff and linkage, but how different is the wiring/computer?
Next, is I'd like to put some cash into it for performance parts, was thinking along the lines of intake, exhaust, chip/tuner, maybe injectors, maybe turbo. I can probably scrounge up 1500-2000 for stuff. I don't need to be the fastest on the track, just want to get a little more out of her. I need to be able to adjust the speedo eventually, would like to possibly have data available through the OBD2, are there units that tune and do that stuff? or am I better off getting separate units?
I plan on making up a new intake and exhaust, in the 4-5inch range, wasn't sure how worthwhile an intercooler would be?
I know there's a bunch of questions about which chip's the best and such, but I'm mainly asking what have yall gotten that you wish you bought sooner?
__________________
1978 Bronco, 96 PSD, ZF-5 trans, 1 Ton Running Gear, and a few other things
You will have to have a ZF tranny from a diesel. The gas bellhousing is different, and cannot be changed. I think the auto computer will work without any trouble. I have heard that it has to be reflashed, but I do not know for sure. The worst that would happen would be tranny trouble codes, such as tranny temp. You will also need the harness for the tranny, for the back up lights and start circuit.
For upgrades, generally a 3" downpipe, 4 or 5" exhaust, intercooler, gauges, and custom chip will probably eat up your budget.
Good luck,
Tim
__________________
"Better to be hated for who you are, than loved for who you're not." - Van Zant
My Truck 1972 F-350 4x4 Extended cab 14-36 Swampers, 97 Powerstroke, 4 position chip with custom tunes, 3" downpipe, 5" exhaust, 99 intercooler, DIY E-fuel, Dana 60 front, 70 rear, lockers in both ends. <font color="blue">72 POWER STROKE</font><font color="red"> INTERIOR PICTURE </font><font color="blue"> ENGINE PICTURE </font>
Wifes' Grocery Getter 99 F-250 SD 4x4 XLT Lariat 4 door. 7.3, Auto, 4 pos Bullydog chip, 3 1/2" downpipe, 5" straightpipe, Genuine Tymar, Stage 1 Monsterbox, 33-12.50-16.5's
sombody already has one, look for him, need wiring harness , PCM would be OK, do not need power mods the lighter chassis is great but with 400hp you'll have drivability adn control issues [img]/ubbthreads/images/graemlins/grin.gif[/img] [img]/ubbthreads/images/graemlins/grin.gif[/img]
__________________ Sold to JCart , 1997 F250 FireTruck Red,CC SB,auto( Presicion TC, HD-2Tugger),5" exhaust, Swamp 140cc injectors, TWildman 4-pos chip,open air cleaner, I/C w Banks intake, ,AIC,dual electric fans,Sky mfg RSK w/ D60w/ARB locker,she's well taken care of now pictures
2004 Dodge 3500 twin turbo 525hp rocket
Man thats allmost as bad to drive as my buddies 460 in a fox stang.! Better have some nuts to drive it hard. [img]/ubbthreads/images/graemlins/biggrin.gif[/img]
__________________
97 F-250 H/D 4 door 4X4 6'bed.Broke block building new engine! Oh well it ran14.96 at 89mph at Baytown!
Kenworth T-600 aerodyne 3406c CAT, with 18* "B" modle injection pump(was a freakin peak yuk),10 over trans,4.10 rears,Dual 150 gal. fuel tanks,Budwieser inspired custom hot rod flames.Going to work real soon Leasing to Landstar yeah!
89 mustang coupe single turbo 302 ,built c-4,running little rubber.
I hate Dodges, straight piped common rail cummings sound like crap!
correct me if I'm wrong but isn't the firewall and tranny floor pan different on 1/2 tons and Broncos vs F250/350's?? I know I looked at my buddies Bronco one time and the floor looked a lot lower on the tranny hump. If you have a body lift it shouldn't matter.
[ QUOTE ]
correct me if I'm wrong but isn't the firewall and tranny floor pan different on 1/2 tons and Broncos vs F250/350's?? I know I looked at my buddies Bronco one time and the floor looked a lot lower on the tranny hump. If you have a body lift it shouldn't matter.
[/ QUOTE ]
Or a peice of sheet steel to add to make the hump taller.
Modifying the hump would be no big deal.
Rick H...
__________________ Omaha Metro Powerstroke Diesel Club
Pres Omaha Metro PSD Club Biodiesel Calculator
HIS
96 F250 4x4 auto super cab.
TS 4 Pos Chip, addaLeaf, Boss 8'-6" plow, , DIY AIC, Tymar DP, gutted EBPV, JS IDM, Tymar Intake, 4" Open exhaust, trio a-pillar gauges + 6 overhead gauges. TruCool 4590 Tran Cooler. On board air with dual horns. 4 corner strobes. AC mod with Twist, ISSPro Turbo Temp Monitor, Power Pedel mod, turbo ped mod, Warn Lock-outs, Swamps 175/173 99 IC & GTS Pipe Kit,Snow Performance Water/Meth inj (NOT hooked up!), chicken to use it!
Garmin GPS,Toughbook Laptop, All Mode Ham Radio.
HERS
97 F250 CC SWB 100% stock and going to stay that way! I lied, Shimmed, Tymar Intake. I lied again, kat dead! More lies.. 3" DP, Gutted EBPV, Turbo Pedistal Mod. Dyno'd 263 hp [color:"RED"] RDRCM#20 [/color]
[ QUOTE ]
correct me if I'm wrong but isn't the firewall and tranny floor pan different on 1/2 tons and Broncos vs F250/350's?? I know I looked at my buddies Bronco one time and the floor looked a lot lower on the tranny hump. If you have a body lift it shouldn't matter.
[/ QUOTE ]
Oh there's a lot of things different. My Bronco is a 1978 model, so I'm not planning on anything to be bolt-on. That's part of the reason I'm doing it, b/c have you ever heard of a PSD in a 78? I've seen cummins and detroit diesels (both mechanical), and I've seen fuel injected gassers, but no electronic diesels. That and I drove the f350 home for $2500. Oh, and I plan on changing the entire wiring harness and some dash components over (gotta make a custom dash to fit the cluster and some controls)
I've already swapped in the ZF5 last year with my 351M, then with my 460. Now to the PSD. Another question you guys may or may not know, is that I was told the castings for BigBlock gas, and Diesel are the same, as with the top two holes, all you gotta do to make the diesel bolt up is hold the adaptor plate against the ZF, and drill some new holes.
And as far as the wiring harness, do you think it might work temporarily? Obviously I'd rather get a new harness, but if I get the thing mounted I'm not gonna let a few tranny codes keep me from driving it.
__________________
1978 Bronco, 96 PSD, ZF-5 trans, 1 Ton Running Gear, and a few other things
i did this auto to manual swap like 3 yrs ago. Wasn't too bad. I cheated though, i used the auto computer in my 97 and it loped everytime i started the truck. I had to trick the tranny thinking it was still in park. To avoid the loping, i had Bill'Chip bump up the idle 25rpm to get rid of the lope. Had to shorten the rear driveshaft, and lengthen front. The steering column I kept the original and took out the auto shifter, and it had the key release hole lever hole already in it. Swap pedal brackets. not hard at all. Oh yeah, the transfer case shifter mounting bracket is different on the ZF than the e40d, you will need a new one of those. The crossmember was different too but i suppose you can adapt your original one.
__________________
1997 F350 CC 4x4 5spd- 4.10, XLT, custom intake, custom 4 inch exhaust, 4 inch lift, cerametallic clutch, Ramsey hydraulic winch, PTO, swamp babies, 6 pos. TS chip, hideaway strobes etc..all the goodies
1995 F350 Wrecker, 4wd, Vulcan 882
so if I get the computer flashed for a 5 speed, is that also what they do to chip it for performance? and what about readjusting the speedometer? Do 'chips' usually replace something? or added on? or are they reprogramming exisitng stuff?
__________________
1978 Bronco, 96 PSD, ZF-5 trans, 1 Ton Running Gear, and a few other things
I saw an older Bronco with a PSD in it in a diesel mag a month ago or so, in the reader's rides section. Very cool. [img]/ubbthreads/images/graemlins/cool.gif[/img]
On the Gas vs diesel bell pattern: NOT as simple as just drilling out some holes. The top 2 holes are the same, but the other holes are not, and there isn't enough material on the trans to drill out new holes. Also, you have issues with the block spacer, crank spacer, flywheel, etc. that's all related to how they go together. Starters are probably different and how they mount, too. Not sure if the GAS motors have even a similar flywheel/clutch as the PSD as the diesel is international and the Gas motors are Ford...
Save yourself a LOT of headaches and just get a PSD ZF.
I went through all of this a few months ago on a conversion. At first it looks straight forward, but it's a LOT of custom fabbing, time, machining, headaches...It's just not worth it...
__________________
Black, '96, F-350, 4x4, Day Cab.
Black/Silver, '97, F-350, 4x4, CC Short Bed. DzlJim.com for some redneck engineered projects.
[ QUOTE ]
At first it looks straight forward, but it's a LOT of custom fabbing, time, machining, headaches...It's just not worth it...
[/ QUOTE ]
well, that's what will make it ALL worth it
And I tried searching for the diesel bronco, couldn't find it, you remember what magazine? If it was 79 or older I'd be real surprised. there's a conversion kit for cummins, and I've seen detroit diesels in that era pickup trucks, so those wouldn't be too difficult of swaps.
And the spacing I can do no problem, I got the ZF to fit with my old 351M, then again with the 460 (although that wasn't as hard), but I did end up using a flywheel off a 390 and redrilled it for a 12.25 clutch. So I ain't skeered of that, and heck, I wouldn't even be opposed to adding a little weld to the case if it's close.
__________________
1978 Bronco, 96 PSD, ZF-5 trans, 1 Ton Running Gear, and a few other things
There's a 72 F350 on here with a PSD, I think he goes by 72 Powerstroke? Suprised he hasn't chimed in. VERY clean install. There's also 78 or so with a 5.9 in it.
__________________
Mine: 91 F250 Reg Cab 4x4 5spd 7.3IDI 4.10LS 145,000 miles. Banks Sidewinder 92 D60 F axle w 97 brakes and Powerlock. Lift: about 4" over stock 250. 33x12.50x16.5 Pro Comp MTs Magnaflow 12" muffler. Sees dirt everyday. Used to haul hay, wood, feed cows, check fence.
Hers: 96F250 CCSB 7.3 PSD 4x4 5spd 3.55 LS 190,000 miles. Puchased 7/03, Looked for a 5spd CCSB for a year!Dana 60 front axle, at stock F350 height (for now) Energy Poly bushings, Bilsteins, 305/70/16 Pro Comps on 16x10 Weld Outbacks, AFE Pro7,TYMAR 3x3.5x4 downpipe,TYMAR 5" straightpipe, gutted EBV, IH Non EBV pedistal,New Alliant AC Injectors,(stage 1)Cal reg kit, SBC Con O clutch, permenent clutch bushing fix, AC mod with a different twist, AMP Powersteps with custom brackets and wiring(one of 2 OBS trucks with them according to AMP) Line of Fire. Sees dirt everyday.
My Company pickup: 86 F250 6.9 C6 320,000 miles Co trucks 5 89 to 94 IDI's, plus about 50 more diesels.
Diesel Mechanic 28 yrs
The AutoGuide.com network consists of the largest network of enthusiast-owned enthusiast-operated automotive communities.
AutoGuide.com provides the latest car reviews, auto show coverage, new car prices, and automotive news. The AutoGuide network operates more than 100 automotive forums where our users consult peers for shopping information and advice, and share opinions as a community.
Linear Mode
