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Discussion Starter #1
ok guys, wanting to install a ZF6 into my '94, looks like the hydraulic clutch components are not the same, so I'm hoping I can use the factory clutch master for the '94, and couple it to the slave for the 2000 ZF6, and hoping that someone else has already done this and know what I'm up against... next issue is the trans input shaft has the failed pilot bearing damage done on it, how is the repair sleeve kit working out for this? or do I bite the bullet and just replace the input shaft?? trans seems to shift fine, rolled it over in every gear and the is little noise, thinking about connecting and electric motor to spin it up good and then cycle through every gear, it is supposed to have about 250,000 miles on and said to work good, owner happened on a deal for a trans with much less mileage on to go into his rig. he pulled his trans originally for a clutch job, and then found the bad pilot after the fact, was his only reason for putting a cheap lower mileage trans back in. last thing is that the truck was auto, and is now manual, and there is a 2003 E450 "F" code 7.3l power stroke going in, do I need to worry about missed signals to the ecu from the missing auto tans from the van??
 

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The zf6 also requires a cooler and you will have to modify your transmission tunnel "hump" in your floor boards.
Your 94 auto trans is not computer controllled you should be able to swap in the manual without needing much wiring or worries about missing auto trans functions.
You can try a search for obs auto to manual conversion, that should have you covered.
I skipped wanting the Zf6 because it has no real advantage over the zf5 I already have, except for a second, second gear. 1st gear and overdrive are the same (or dang close to) the zf5
 

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Discussion Starter #3
the pcm I will likely be using out of the van, which is an electronic trans, so it sounds like I just need to remove the range sw of the trans and leave it plugged into harness in park.
not finding much in the way of a cooler, looks like it just gets plumbed to the rad anyway... pretty handy with hard pipe so I'll just bend up a new set of lines for it.

truck is getting a 1.5" body lift, that should clear the trans I'm hoping, or be dang close!

T case is manual shift, so that should be a breeze.

Thanks again!
 

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This has been done successfully. There are a lot more details, best to search for the thread. I recall the block adapter plate is different, the clutch spline is different. Driveline length Crossmember. Last of all I believe the spline on the transfer case coupler is different so the 99 up transfer case was installed as well. Don't quote me on this, look it up. This is the off the top of my head memory of something I considered doing. Definitly need more donor parts than just the trans itself. Shifter stub is another IIRC. I wouldn't do it without a donor truck.

Also for the record, the input shaft pilot bearing area repair sleeve kit works if it is the one with a hardened ground and polished thick race to install on the shaft stub and a new larger ID roller bearing.
 
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