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Old 10-13-2013
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Icon4 Auto to manual swap electrical problems

I just swapped my pickups automatic trans with a Manual I've got the 4.0 in a 2004 with 4x4 and it all went in easy enough but it won't idle, I put the neutral safety switch in neutral and it will turn on but it idles rough and won't let the engine over 3000 rpm and no speedo or 4x4. I know it's all electrical just need to know what parts or harness I'll need to get it running smooth. Thank you

Last edited by Cody.mckinley; 10-13-2013 at 05:36 PM. Reason: Grammar
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Old 10-13-2013
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Easiest is to get the computer and engine/trans harness from another 4.0 that's a manual. I suggest the junkyard... Depending on how you source that material a tuner/custom tunes could be similar in cost but usually more. I'm running a ranger comp. in my explorer w a modded harness but still throw emissions codes due to differences.
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Old 10-14-2013
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Alright and the harness needs to be the entire engine and trany harness? and isn't there another harness assembly under the dash or could I just get the clutch position sensor and if so where would I splice that to? I've got a flashed Manual computer already and it didn't crank with it installed all the accessories worked though.

Last edited by Cody.mckinley; 10-14-2013 at 03:16 PM. Reason: Grammar
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Old 10-15-2013
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The computer may have different pins than your harness. Having the having the complete harness for that computer helps eliminate issues unless u are a wiring genius. Thats why I still have emissions codes. Explorer harness with a ranger computer and a pigtail for the transmission.
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Old 10-15-2013
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The neutral safety switch. You said you put it in neutral. Are you still using the auto range selector? Under the dash by the pedals the manual neutral safety switch hooks up to the master cylinder. Should be prewired harness since it makes fords life easier to produce a sincle harness for multiple applications. My 5r55e to M5OD-R1HD swap - Ford Explorer & Ranger Resource "Serious Explorations"

I cover some of the wiring stuff on here if u wanna look. Its incomplete but it may help. Theres a pic of the NSS that goes w the master and some stuff on the pigtail. Hope I'm being helpful.

Last edited by moneypit; 10-15-2013 at 11:55 AM.
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Old 10-15-2013
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Okay thank you I'll look for the whole harness somewhere which is hard without a donor truck and that should help I believe the tranys an 02 would the connections be any different you think?
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Old 10-15-2013
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things change between years even in the same generation. best bet is to get a pinout or wiring schematic for each truck and compare to make sure you have the right wires youre hooking into. my donor vehicle was a ranger at the junkyard of the same year and engine so wires were the same color for what I needed. but i made the mistake of anly geting the trans harness and using it to splice into the connections I needed from the original harness.

(most of my info is on older stuff than '01 so take this paragraph with a grain of salt i dont want to be spreading false info). (
the manual trans is pretty simple for wiring. Its really just a backup sensor and the starter relay wires (neutral safety loop) and I guess for some a speed sensor(?). thats only 4-6 wires and they all hook to the range sensor wires. I think between the older rebuild I have and the newer manual trans the difference is the newer ones are an HD version so they have an extra bell housing bolt for the sohc and slightly stouter gearing. the rest should be the same with (potentially) a speed sensor in the tailhousing. You have an 04 so you may need it nullifying the next statement. unless your truck had one before it isn't really needed but to keep the hole plugged since you should have one in the output of the t-case that the truck uses. (thats how it would be if I put an HD in my rig) that being said I would guess your year and an 02 probably have the same wiring colors as eachother.

I actually just spliced everything in so if for some reason I ever want I can go back to automatic with minimal effort and a un-tune since Im going to tune my auto comp to run my manual. i think the pics in my other thread on EF show that pretty good...actually i just checked and it doesn't.. but, i spliced that pigtail into the wires I figured out and left the original harness plugs intact to dangle from where their secured.

for you best/cleanest set/up is computer and full harness engine and trans from said truck. it has to be the same engine w the manual so the comp/harness will match up.

Last edited by moneypit; 10-15-2013 at 06:39 PM.
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Old 10-17-2013
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alright im going to be looking around for the whole harness i believe it needs to be 4x4 as well its got a wire going to the transfer case motor. thank you for the help!! ill post again if i find what im looking for and get her running again!!
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