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 DSCF2317 - MT swap parts haul.jpg | Hits: 47 | Size: 57.71 KB | Posted on: 7/23/20 | Link to this image
Started collecting parts for a M/T swap. Pretty good first haul.
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 DSCF2321 - 5spd pedals surface rust.jpg | Hits: 47 | Size: 48.07 KB | Posted on: 7/27/20 | Link to this image
M/T pedal set, exhibiting the typical surface rust. Pay attention to the tip of the master cylinder's pivot rod attachment at the far right... The eye of the rod is visible at the top left, along with the very fragile plastic pushing that clips on.
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 DSCF2323 - 5spd pedals MC arm pivot shaved.jpg | Hits: 51 | Size: 50.35 KB | Posted on: 7/27/20 | Link to this image
Heim Joint Mod alternative: I could have gone with a 7/16" stop collar, but it fit slightly loose and was bulkier than I wanted for that narrow space, so I shaved the tip down ever so slightly to allow a thinner 3/8" collar to fit. That also lines the set screw up better with the valley, while still leaving enough room for the MC rod's eye.
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 DSCF2330 - 5spd pedals painted.jpg | Hits: 52 | Size: 56.3 KB | Posted on: 7/27/20 | Link to this image
M/T pedal set; surface rust cleaned up, fresh coat of paint applied. No wear visible or play in the bushings, and no wear to the MC rod pivot arm, so I opted to not replace those.
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 DSCF2333 - 5spd pedals shaft collar heim joint alternative.jpg | Hits: 43 | Size: 39.98 KB | Posted on: 7/27/20 | Link to this image
Heim Joint Mod alternative: 3/8" shaft/stop collar and the plastic "teeth" of the bushing trimmed to act only as a sleeve. No need to fuss with what length to cut the rod to, or being off a spline with the pivot arm.
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 DSCF2352 - donor clutch 11 inch.jpg | Hits: 55 | Size: 72.89 KB | Posted on: 8/6/20 | Link to this image
Got lucky with the donor clutch being the upgraded 11" and looking fairly new.
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 DSCF2358 - donor flywheel condition.jpg | Hits: 54 | Size: 63.52 KB | Posted on: 8/6/20 | Link to this image
Got less lucky with the flywheel condition.
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 DSCF2358 - donor flywheel condition b.jpg | Hits: 57 | Size: 39.94 KB | Posted on: 8/6/20 | Link to this image
Close-up of the donor flywheel condition.
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 DSCF2366 - M5OD gears inspected.jpg | Hits: 49 | Size: 61.63 KB | Posted on: 8/8/20 | Link to this image
Cleaned and cracked open the case, gears look good.
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 DSCF2367 - M5OD gears inspected.jpg | Hits: 54 | Size: 50.13 KB | Posted on: 8/8/20 | Link to this image
Cleaned and cracked open the case, gears look good.
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 DSCF2365 - M5OD slave cylinder.jpg | Hits: 39 | Size: 60.09 KB | Posted on: 8/8/20 | Link to this image
Bellhousing mostly cleaned (donor engine leaked A LOT of oil), slave cylinder looks good to my untrained eye.
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 DSCF2382 - firewall cover difference.jpg | Hits: 46 | Size: 54.21 KB | Posted on: 8/15/20 | Link to this image
Firewall covers differ by year, apparently. On the left, '96 M/T cover with master cylinder cutout. On the right, '92 plug. The '92 plug is the exact shape of the inner portion of the '96 cover.
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 DSCF2383 - firewall cover difference.jpg | Hits: 37 | Size: 46.77 KB | Posted on: 8/15/20 | Link to this image
'92 firewall...the '96 cover doesn't fit within the outer lip; you can see the '92 plug's outline right up against the lip. I didn't pay close attention at the time, but I'm thinking the '96 didn't have that lip.
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 DSCF2394 - electronic vs manual t-case linkage plate.jpg | Hits: 40 | Size: 40.67 KB | Posted on: 8/19/20 | Link to this image
Transfer case shift linkage plates have different bolt patterns...will need to modify or replace. Electronic on the left, manual on the right.
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 DSCF2405 - electronic vs manual t-case linkage plate.jpg | Hits: 47 | Size: 38.43 KB | Posted on: 8/20/20 | Link to this image
M5OD t-case linkage plate bolted on, E4OD linkage plate placed in front (left bolt blocked from view by top bolt) to show alignment differences. The E4OD's right bolt aligns perfectly with the M5OD's unused middle hole.
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 DSCF2409 - electronic vs manual t-case linkage plate.jpg | Hits: 41 | Size: 45.77 KB | Posted on: 8/20/20 | Link to this image
Side-by-side view of the E4OD t-case shifter linkage plate (left) and M5OD plate (bolted on at right). The portion with the right bolt on the M5OD plate needs to get added into the E4OD plate.
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 DSCF2448 - proper 4WD crossmember.jpg | Hits: 49 | Size: 27.49 KB | Posted on: 8/26/20 | Link to this image
Three yards and four donor trucks later...the pieces necessary to reconstruct one good 4WD M/T SBF crossmember. Pickers can't be choosers.
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 DSCF2451 - 4WD crossmember patched up.jpg | Hits: 45 | Size: 20.54 KB | Posted on: 8/27/20 | Link to this image
4WD crossmember patched up.
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 DSCF2449 - 4WD crossmember patched up.jpg | Hits: 56 | Size: 20.93 KB | Posted on: 8/27/20 | Link to this image
4WD crossmember patched up.
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 DSCF2453 - 4WD crossmember patched up.jpg | Hits: 57 | Size: 36.37 KB | Posted on: 8/27/20 | Link to this image
Transfer case fits now with the proper crossmember!
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 DSCF2454 - M5OD vs E4OD manual case shift linkage.jpg | Hits: 65 | Size: 48.59 KB | Posted on: 9/1/20 | Link to this image
M5OD vs E4OD manual t-case shift linkages. The M5OD plate adds the extra width up top for the third bolt hole (needed to line up with the tranny's holes) and is the same width as the E4OD plate on the bottom half. Ford should have made a single plate the width of the M5OD up top, and slightly wider than both on the bottom so as to not have the weak point at the 4-low stop.
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 DSCF2455 - M5OD shift linkage reinforced and rust treated.jpg | Hits: 43 | Size: 45.67 KB | Posted on: 9/1/20 | Link to this image
M5OD t-case linkage plate's weak point reinforced, rust treatment done for painting.
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 DSCF2458 - M5OD shifter position - fourth gear.jpg | Hits: 47 | Size: 60.83 KB | Posted on: 9/1/20 | Link to this image
Shifter installed, just enough jump seat clearance in 4th gear.
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 DSCF2459 - lengthened rear driveshaft.jpg | Hits: 39 | Size: 23.88 KB | Posted on: 9/1/20 | Link to this image
Lengthened driveshaft is a perfect fit.
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 DSCF2461 - BW1356 one-piece shift lever.jpg | Hits: 40 | Size: 33.45 KB | Posted on: 9/1/20 | Link to this image
One-piece shift lever on the BW1356 transfer case.
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 DSCF2502 - throwout bearing-PP relaxed state.jpg | Hits: 55 | Size: 28.91 KB | Posted on: 9/9/20 | Link to this image
Still can't get clutch to disengage... Best pic I could get of the throwout bearing and pressure plate in their relaxed state. Bearing travel with the pedal pressed looks close to spec, but I haven't tried getting an exact measurement yet. Had hoped to see in between the PP fingers with a borescope, to see if FLYWHEEL SIDE marking faces rearward (i.e., installed backward), but couldn't get a view of anything.
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 DSCF2492 - throwout bearing-PP relaxed state.jpg | Hits: 66 | Size: 33.99 KB | Posted on: 9/9/20 | Link to this image
Similar view of the throwout bearing and pressure plate in their relaxed state.
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 DSCF2507 - right xmember perch tight fit.jpg | Hits: 63 | Size: 50.64 KB | Posted on: 9/28/20 | Link to this image
Can squeeze the right upper perch in, but it's too tight against the exhaust pipe to push it in enough to get the top bolts in.
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 DSCF2514 - right xmember perch modded.jpg | Hits: 44 | Size: 70.73 KB | Posted on: 9/28/20 | Link to this image
Modified the right upper perch: trimmed the top so it can be pushed further away from the exhaust pipe, moved the top bolt holes in to line up with the frame rail's holes, and trimmed off the stupid lower rear lip that functions only to make you remove the perches before removing the crossmember.
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 DSCF2515 - right xmember perch modded.jpg | Hits: 52 | Size: 54.03 KB | Posted on: 9/28/20 | Link to this image
Modified the right upper perch.
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 DSCF2518 - right xmember perch installed.jpg | Hits: 47 | Size: 47.68 KB | Posted on: 9/28/20 | Link to this image
Installed the right upper perch; has a sliver of daylight now between it and the exhaust pipe.
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 DSCF2519 - right xmember perch installed.jpg | Hits: 52 | Size: 43.8 KB | Posted on: 9/28/20 | Link to this image
FYI: I trimmed a little more than needed off the top of the right upper perch. Everything lines up nicely and it has more of a gap to the edge of the frame rail than I expected.
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 DSCF2522 - right xmember perch installed.jpg | Hits: 49 | Size: 39.74 KB | Posted on: 9/28/20 | Link to this image
I had to move the catalytic converter ~0.5" downstream in order for it to clear the upper perch.
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 DSCF2922 - weird 1993 master-slave cylinder.jpg | Hits: 80 | Size: 41.15 KB | Posted on: 2/8/21 | Link to this image
Weird master-slave cylinder found on a 1993 F150 (M5OD-R2).
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 DSCF2923 - weird 1993 master-slave cylinder.jpg | Hits: 64 | Size: 67.03 KB | Posted on: 2/8/21 | Link to this image
Weird master-slave cylinder found on a 1993 F150 (M5OD-R2).
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 DSCF4237 - M5R2 locating peg fight.jpg | Hits: 48 | Size: 33.16 KB | Posted on: 9/16/22 | Link to this image
Pulling the M5R2 for a ZF5 swap resulted in 2+ hours of fighting to get it free, and one of four ratchet straps used simultaneously snapping the webbing in half. When it did pop loose, it took one of the locating pegs with it.
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 DSCF4235 - ZF5 slave cylinder interference.jpg | Hits: 41 | Size: 62.22 KB | Posted on: 9/16/22 | Link to this image
WTF? My slave cylinder doesn't fit into the shallow opening for the disconnect. Dremel time.
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 DSCF4236 - ZF5 slave cylinder interference.jpg | Hits: 47 | Size: 65.22 KB | Posted on: 9/16/22 | Link to this image
Fits properly now.
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 DSCF4241 - ZF5 shifter.jpg | Hits: 42 | Size: 58.26 KB | Posted on: 9/16/22 | Link to this image
Added a lil' bling to the ZF5 shifter.
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M/T Swap