Haha. Well took us 3 hours to rip out the auto tranny... Got everything out except the trans cooler and pedals. But I spent time earlier today with them so that's a quick swap. 5 mins.
Here's some teaser shots...
We still need to go get a new pilot bearing for the flywheel. The one that was supposed to come in my clutch kit wasn't there. After that I think we'll have all the parts we need to finish it up. Should be driving by 2 or 3pm tomorrow. I'll go from there to see if I NEED to swap wiring harnesses after putting in the manual PCM. It might bypass the plugs for the automatic that isn't there anymore.
I tell you what though. Cranking the motor over with slippery hands on the TC is not fun or easy.
Test drive was performed at approx 10:30pm. 2002 4.0 4x4 manual PCM flashed the 'theft' light fast...PATS issue. stock 2001 4.0 4x4 auto PCM was reinstalled and the gear switch was pulled off the auto and made the computer think it's in neutral. Next time he's home, we're going to head over to Ford with my truck and VIN, so we can flash his PCM to a 2001 4.0 4x4 manual truck. That should allow him to throw in the manual truck harness and everything to work properly.
Bleeding a dry clutch system is sorta a pain! lol.
Beard.....I completely forgot about the engine being angled downward and the torque converter being full of fluid! lol.
All the parts needed for the swap minus the clutch kit:
Inspection plate installed and how I route wires to under the hood:
Removing the automatic tranny:
Me pulling the torque converter:
Flex plate and Torque converter removed:
Gutting the interior of automatic components:
Shane's leaky tire in my driveway:
Shane wrenching on the flywheel and clutch:
Random garage parts shot:
All automatic stuff (minus the flexplate):
Manual tranny installed:
Another Shane original lol:
All interior pieces complete and put back together:
Here's what people want to know. Hurst shifter with a body lift and what it looks like:
Everything re installed (minus front shaft for testing):
Now Austy came to the rescue last night. Helped me pull my gear selector dealy off and bleed my clutch and test drove it with me. A Pic with his superlift and coils and my RCD.
So all in all I have about 16 hours into the swap not including clean up and Shane has about 13 or so. Thanks a lot Shane. You are the man! I owe you big for stickin with me and helping me do this. This goes to show everyone this kind of swap can be done in a garage with just basic tools and air and an extra couple sets of hands. Also like to thank billy and my buddy frame and austy. Basically anyone who helped me.
Now as far as the finished product. I don't have my speed sensor hooked up. I'm not sure on how we're going to get that working but I know I need it soon. I have the other harness and pcm from that truck still. I also have to use my automatic pcm otherwise the pats system goes off and I can't start it. Using the automatic pcm (for the time being) means I had to pull the gear selector piece of my automatic and click it in neutral in case I need 4wd and plugged it in. But being that it's an automatic pcm, it has the factory rev limiter at 3,000 rpm. So when I'm going say in first gear I can't take it past 3k RPM before the rev limiter kicks in.... So I haven't been able to feel the power difference if there is any at all.
Any suggestions guys? I'd really like to see if Bob will chime in.