M5ODR2 conversion complete

[bronkenn]

Thanks for all the info Timmy! I just ordered the slave, master and LUK clutch from Rockauto. The hose is out of stock, but BC Broncos has a stainless ZF hose that should work. Unfortunately my M5OD is one with the forward shifter, but I think I’m just gonna fab up a shifter that will clear the dash.

https://classicbroncos.com/forums/threads/engine-and-trans-swap.309628/post-3369210

 

[dmoses42]

Tim,

Couple of quick questions... Which starter and block plate did you use? Looking at AC Delco starters on RockAuto, 1996 F150 5.0 vs 2003 F150 4.2. There are 2 differences listed which AI says are due to block plate thickness differences between the two. Mounting Flange to End of Case: 1996 is 180mm, 2003 is 201.1mm; Mounting Flange to Pinion End at Rest: 1996 is 7mm, 2003 is 14mm. AI says to use the one from the 4.2 since that is what the transmission is from, but I have a hard time fully trusting something without a heartbeat so I wanted to ask here.

Second, did you use a 10 inch or 11 inch clutch?

Thanks,

Don

 

[Timmy390]

Tim,

Couple of quick questions... Which starter and block plate did you use? Looking at AC Delco starters on RockAuto, 1996 F150 5.0 vs 2003 F150 4.2. There are 2 differences listed which AI says are due to block plate thickness differences between the two. Mounting Flange to End of Case: 1996 is 180mm, 2003 is 201.1mm; Mounting Flange to Pinion End at Rest: 1996 is 7mm, 2003 is 14mm. AI says to use the one from the 4.2 since that is what the transmission is from, but I have a hard time fully trusting something without a heartbeat so I wanted to ask here.

Second, did you use a 10 inch or 11 inch clutch?

Thanks,

Don

I used the engine plate and flywheel off the stock 302 28oz balance. Stock 302 starter as well. My donor was an automatic E350 van so not much I could use there......

Clutch, I used the LUK diaphragm style (not the 3 fingers that came originally) that was already on my 302...11 inch....it was only 2 years old. The throw out bearing was/is hydraulic. Used the one listed for the year F150 the M5 came out of. I Got a folder with all the receipt and parts numbers someplace.....
https://www.wildhorses4x4.com/early...wcB&gbraid=0AAAAAD8cIr-PgfpacHFrrfXnfwokEzzjb

Tim

 

[dmoses42]

Ok, cool. So I guess as long as the starter matches the block plate (and not for an auto trans), there shouldn't be any issue with flywheel engagement. And I was already leaning towards a 11 inch clutch, but RA lists a 10 and 11 for the '96 F150. I bought a M5OD-R2 out of a 2003 4wd 4.2 F150 over the weekend from the junkyard. $220 out the door. Appears to be really low miles so I thought I got a screaming deal, til I got home with it and the input shaft wouldn't make a full turn in neutral. Popped the top cover off and the input shaft and counter shaft have some broken teeth, and well as a broken tooth on the 3rd output shaft gear. The rest of the insides look good (almost new, really) but I haven't fully disassembled it yet. The sliders even still have most of the manufacturing marks on them. I moved to the front cover and found that the input bearing is bad. The top cover and front cover had both been off, made noticeable by copious amounts of grey RTV squeezed out from them. When I pulled the front cover off I think I found why the bearing failed. The hole that the oil trough fits in to allow lube to the front of the bearings was plugged with RTV. I'm hoping the parts I already listed are all that is bad. Those, and a bearing kit, plus the $220 I gave for the trans brings me to right at $650 for a virtually brand new transmission. More work than I had hoped for but that's how you learn. Still a good deal in my opinion.

 

[.94 OR]

I hope the tear down and parts replacement goes well.
I am following along to see if a body lift is in order to clear the shift tower or the D20 under the body brace.