I love manual transmissions so I'm upgrading my truck as Ford isn't currently making a truck with a manual trans.
I have a few questions I need help with for my Daily Driver swap.
The plan is to get everything ready before taking my DD apart, Prep time may be a few months because of costs mostly.

I have a 3.0 truck 4wd (manual) and a 4.0 4wd (manual) donor truck both 1998's.
I'm doing the engine swap, and want to use a different manual trans.... the Heavy Duty 5 speed manual from a later year SOHC truck. I'm guessing that it has bigger bearings as the ratios are said to be the same.

1. I've read that the SOHC HD trans will work with the 4.0 OHV engine, but do I use an OHV flywheel, starter, and clutch setup, or do use a SOHC flywheel, starter, and clutch setup?
2. What company does the best rebuilds on manual trans?
3. I'm also looking into getting a lightened (16.5 Lbs.) flywheel for quicker acceleration. Has anyone run one of these in their DD?
4. I want to rebuild the transfer case while it's out, but have not found a video of anyone doing a BW 1354. Does anyone have a set of instructions or vid?

 

4.0l M5OD-R1(manual trans) and 4.0l SOHC M5OD-R1HD are the same internally, the HD means the case has an extra bolt hole on bellhousing, that's why the "HD" was added, doesn't really stand for Heavy Duty
Yes, R1HD will bolt to the 4.0l OHV engine, you will just have a open bolt hole in bell housing, which is fine, its extra, all the usual OHV bolt holes are there
OHV and SOHC used the same flywheels 1997 and up, 8 bolt, 1996 and earlier used 6 bolt, but same size and same clutch

4.0l's, OHV and SOHC and 3.0l's all used different "Y" pipes for exhaust, from there back 3.0l and 4.0l exhaust is the same

I would do a separate post for the engine modifications and programming

 

Thanks, and that's helpful information!
Knowing the only difference in trans is a bolt hole clears up the HD thing.
I'll make another thread for the other stuff.
Edited this thread as well.

 

I spoke with one of the guys from the parts store, and two separate flywheels are listed...one for the 98 and a different one for the 2010. I'm guessing that the newer one may be a different material for higher rpm but that is just a guess.
The clutch was the same between the two if choosing stock.

The guy mentioned that a flywheel shim was available.
I've never heard of one of those.
What is the use for them, and are they needed or just an option?