96 f250 e40d to zf5 swap - PowerStrokeNation : Ford Powerstroke Diesel Forum
 
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post #1 of 9 (permalink) Old 09-10-2016, 01:03 AM Thread Starter
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96 f250 e40d to zf5 swap

Hi, I am new to powerstroke nation and I am having a serious problem I am hoping to get resolved. I recently did an e40d to a zf5 swap. I used the transmission and transmission wiring harness out of a 93 f-250 7.3 idi and I have a 1996 f-250 powerstroke. Everything is done and now it cranks but don't start. I have plugged in my clutch safety switch, I have jumped my neutral safety switch wires, pin 4 and pin 12 up under the brake master cylinder. Now when I turn my key forward my check engine light and my wait to start light blink. Also my idm relay clicks. I plugged my scanner into it and it has no codes. It will crank all day just not start. The e40d transmission harness had two plugins up under the brake master cylinder, the big square one and a small 2 wire round plugin and the zf5 harness only has the big square plugin, not the small 2 wire round plugin, does anybody know what that small round 2 wire plugin is for? Any help would be great!!! Thanks!! If you have anymore questions just ask.
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post #2 of 9 (permalink) Old 09-10-2016, 03:03 PM
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Re: 96 f250 e40d to zf5 swap

Try plugging the e40d harness back in and put the selector in park or neutral. That should work. That's what I did on mine and just zip tied it up. Idk if it's the harness from the idi that's not compatible room something else?

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post #3 of 9 (permalink) Old 09-10-2016, 07:37 PM Thread Starter
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Re: 96 f250 e40d to zf5 swap

Thanks for the reply! So I just tried to install the auto wiring harness and but the range selector in park and also tried neutral, same thing happened, wait to start light and check engine light blinked and would turn over with no start. Also idm relay still clicking. Everything has gone well with the swap other than this no start issue.
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post #4 of 9 (permalink) Old 09-10-2016, 10:08 PM Thread Starter
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Re: 96 f250 e40d to zf5 swap

So i found if i jump the pcm wires on my glow plug relay it starts and after it warms up i can disconnect the jumper wire and it is fine, so im thinking i need a pcm out of a truck with a manual transmission? Or to do it the cheap way i could toggle switch it.
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post #5 of 9 (permalink) Old 09-10-2016, 10:15 PM
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Re: 96 f250 e40d to zf5 swap

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Originally Posted by Thatchevyguy View Post
Try plugging the e40d harness back in and put the selector in park or neutral. That should work. That's what I did on mine and just zip tied it up. Idk if it's the harness from the idi that's not compatible room something else?
It's a weird one.
From what I understood, it cranks but won't start. Wouldn't the MLPS keep it from cranking over completely?
I believe the trans part of the harness just unplugs on the frame rail, then you just plug in the zf one. (From a swap I saw previously)

I also don't think the auto vs manual pcm will keep it from starting.

I'm not sure what you mean by jumping it on the glowplug relay.

Swap the relays around and double check all the fuses.

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post #6 of 9 (permalink) Old 09-10-2016, 11:09 PM
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Re: 96 f250 e40d to zf5 swap

Auto to manuel computer makes no difference. And I should clarify what I meant by selector. I completely removed the auto shifter itself from the truck but still have the auto column. What I meant was the plastic piece that bolts on to the side of the tranny. It is hooked up with the linkage. Make sure that is in park or neutral.

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post #7 of 9 (permalink) Old 09-12-2016, 12:28 AM Thread Starter
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Re: 96 f250 e40d to zf5 swap

I knew what you meant by the selector, and that is exactly what i did, still didn't help. The glow plug relay has 4 posts on it, the two smaller ones are red pcm wires, if i jump those two posts it starts with no hesitation, and when i jump it the wts light and check engine light work properly, when i disconnect the jumper wire they flash. I tried a new glow plug relay, it did nothing. I have done this swap before and never had this happen. This one is stumping me though.
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post #8 of 9 (permalink) Old 09-12-2016, 04:17 AM
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Re: 96 f250 e40d to zf5 swap

You said the IDM relay was clicking, replace it. Along with the pcm relay.

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1979 chevy c30 dually, sm465, 373's? Converted to 6.2 diesel, pump turned up and advanced a hair.(wrecked)
1994 ford F350 dually 4X4: 7.3 powerstroke, 5 speed. 6637, straight pipe into dual stacks. Cooper discoverer at/3's.
2010 Jetta TDI 40 or so mpg :flippa:
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post #9 of 9 (permalink) Old 09-20-2016, 12:22 PM
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Re: 96 f250 e40d to zf5 swap

check your clutch 3 position switch again make sure its holding in place and make sure its plugged all the way in with no corrosion

The NSS circuit passes through that switch. On a auto truck the NSS circuit continues through the DTRS so it will only start in P or N. On a manual truck the NSS wires just simply bypass the auto trans. I think you have something wrong with your NSS circuit, the truck does not know you have clutch fully depressed???

I am not sure why the CEL light is flashing? That is a bit odd.
Check the wiring of the neutral safety circuit

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