1997 F350 CCLB 4x4 Cummins ZF5

jcarrick

jcarrick

New member
Joined
Nov 7, 2012
Messages
137
Hey guys,

This past summer i finished my conversion project, but as everyone knows they are never really finished. Like the title says, i did 1997 F350 Crewcab Longbed 4x4 with a 2nd gen 12v and the S5-47 Zf5 speed. The motor is a 215 motor with a #0 plate, timing @ 17*, wastegate welded due to running an industrial manifold and no room for a wastegate and a 4" exhaust and intake. Im running a 500hp/1000ftlb southbend clutch with 3:54 gears and 35" tires. I really like this setup, except that the clutch is too late and will slip with a load in 4th gear at around 25-30 psi. I was told this clutch would handle it, but DCS was wrong. After telling southbend about this they said they would give me a little bit of a discount on a dual disk. So when this one is totally done i will upgrade. I have put about 20k miles on it since it was converted. It is averaging 23.5 mpgs on the highway and 20-21 in town. I am getting 17-18 towing my 21 foot wakeboard boat. Overall i am very happy with truck and how it runs. The only issue is that since doing the conversion it is hard to get it into 1st, 2nd, and reverse without going into 4th first. I have been told that this is because the clutch is too heavy for the master cylinder and that they make an aluminum master that has more volume and will cure the problem. I have only heard this from one person and have not tried it yet. Hopefully i can get some more info on that soon. Here are some pics of the truck in its current form:

Bringing home its new heart
[ame="http://s66.photobucket.com/user/jcarrick/media/86CA9AD6-AAF1-4CD0-B7D5-7B56B5A428CD-5302-00000235149C44B1_zps90093ef0.jpg.html"]86CA9AD6-AAF1-4CD0-B7D5-7B56B5A428CD-5302-00000235149C44B1_zps90093ef0.jpg Photo by jcarrick | Photobucket[/ame]

Motor Cleaned up, except the valve covers
[ame="http://s66.photobucket.com/user/jcarrick/media/null_zpsb3d6b9b0.jpg.html"]null_zpsb3d6b9b0.jpg Photo by jcarrick | Photobucket[/ame]

Sitting in the truck
[ame="http://s66.photobucket.com/user/jcarrick/media/null_zpsadf34b4f.jpg.html"]null_zpsadf34b4f.jpg Photo by jcarrick | Photobucket[/ame]

Making the dodge intercooler fit
[ame="http://s66.photobucket.com/user/jcarrick/media/null_zpsd1e4864d.jpg.html"]null_zpsd1e4864d.jpg Photo by jcarrick | Photobucket[/ame]

[ame="http://s66.photobucket.com/user/jcarrick/media/null_zpsb3b9a9b7.jpg.html"]null_zpsb3b9a9b7.jpg Photo by jcarrick | Photobucket[/ame]

[ame="http://s66.photobucket.com/user/jcarrick/media/null_zpse8d5fa83.jpg.html"]null_zpse8d5fa83.jpg Photo by jcarrick | Photobucket[/ame]

[ame="http://s66.photobucket.com/user/jcarrick/media/null_zpsdd206d7b.jpg.html"]null_zpsdd206d7b.jpg Photo by jcarrick | Photobucket[/ame]

[ame="http://s66.photobucket.com/user/jcarrick/media/null_zpsf2c7e7b5.jpg.html"]null_zpsf2c7e7b5.jpg Photo by jcarrick | Photobucket[/ame]

[ame="http://s66.photobucket.com/user/jcarrick/media/null_zps01e579e8.jpg.html"]null_zps01e579e8.jpg Photo by jcarrick | Photobucket[/ame]

All back together with a Sky Manufacturing 3" RSK kit and new shoes :)
[ame="http://s66.photobucket.com/user/jcarrick/media/null_zpsb21d26ae.jpg.html"]null_zpsb21d26ae.jpg Photo by jcarrick | Photobucket[/ame]

[ame="http://s66.photobucket.com/user/jcarrick/media/null_zps15f252a5.jpg.html"]null_zps15f252a5.jpg Photo by jcarrick | Photobucket[/ame]

Hope everyone enjoys! I will post up the future plans tonight or tomorrow.

-Jon
 
Yes if you use them right. you used the URL code not the IMG code. You have your Library set to private that is one of the reasons it's acting up.
 
null_zps15f252a5.jpg
 
Since i cant seem to figure out how to edit my first post i will put my pics from the first post here.

Bringing home its new heart
86CA9AD6-AAF1-4CD0-B7D5-7B56B5A428CD-5302-00000235149C44B1_zps90093ef0.jpg


Motor Cleaned up, except the valve covers
null_zpsb3d6b9b0.jpg


Sitting in the truck
null_zpsadf34b4f.jpg


Making the dodge intercooler fit
null_zps999b92b4.jpg


null_zpsd1e4864d.jpg


null_zpsb3b9a9b7.jpg


null_zpsdd206d7b.jpg


null_zpse8d5fa83.jpg


null_zpsf2c7e7b5.jpg


null_zps01e579e8.jpg


All back together with a Sky Manufacturing 3" RSK kit and new shoes
null_zpsb21d26ae.jpg


null_zpsdcc1af1f.jpg


-Jon
 
Very nice work. It looks nice and clean. Is that the big block ZF 5S-47? Also what kind of RPMs do you run at hyway speed with the 35s and 3.54s? I'm researching my 12v swap, so I'm very curious to know what works to get that kind of MPG. Thanks, and congrats, good work again.
 
I hate that last picture, makes me think about my Supra that will be in storage for another 5 months. Nice looking truck.
 
Thank you for solving my intercooler problem! Ready to hack my core support now!

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Mendomotox,

Yes it is. I have not hooked up my tach yet because DCS cant figure out how THEIR OWN sensor is supposed to be wired, but calculated RPM at 80 in 5th gear is 1800. Once i get the tach figured out i will be able to give you a little more accurate info.

6.4 F350,

I know what you mean. I put mine away at the end of October and wont have it back out until March. We were riding 3 days a week though until the lake got too low and we couldnt store the boat outside anymore due to the cold.

G1625S,

Not a problem, let me know if you have any more questions about it. I had to re-located my battery tray because of where the ends of the intercooler came through. I will post up a finished engine bay pic soon.
 
Wow that's a pain about your tach sensor, good luck getting it working. I woul be interested to see the actual cruising RPMs. Are you using the 460 radiator too? How is it handling it? Also which adapter plate are you using that allows you to use a dual disc clutch? I thought I remember destroked saying you couldn't with theirs.
 
Ya, I'm gonna get it working one of these weekends, but right now I need to finish a 79 ford conversion for a customer. Yes, I'm using the 460 rad and it's working great. Temp gauge gets to the low part of the normal section and rarely moves past that unless towing a heavy load in the middle of summer at which point it sill doesn't clime much at all. The adapter plate is from Diesel Conversion Specialists as well. According to southbend it will handle at least a dual disk, but I have no concrete proof of that....yet. Haha


Sent from my iPhone using Tapatalk
 
Ok I'll have to do some more research on the dual disc deal. I'm guessing with my plans I'll be wanting one too. Or I can just wait till you get your figured out lol. I just had a thought about your hard shifting. You may already know this and if so I don't mean to be a pompous ass. But, have you looked at your bushing on the clutch master cylinder push rod? I had to retrofit a hiem joint on mine on my old 97 PSD. I think I have pics of mine if you want I can try to figure out how to post them. Just trying to save you some time.
 
jcarrick said:
Mendomotox,

Yes it is. I have not hooked up my tach yet because DCS cant figure out how THEIR OWN sensor is supposed to be wired, but calculated RPM at 80 in 5th gear is 1800. Once i get the tach figured out i will be able to give you a little more accurate info.
Click to expand...

You seem to be a little rough on DCS. I worked with them on a swap and they were great. I also has a little bit of an issues with the tach sensor, but an hour of working on it, adjusting and swapping the poles like they said it worked fine and it is very true.

What's your situation with the tach sensor?
 
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Mendomotox,

I'm not sure when I'm gonna get the dual disk it, but I really think the plate doesn't matter that much. According to south bend it's the size of the zf5 bell housing that makes a big difference, but like I said I'm not sure. I would very interested in seeing what you're talking about. I want to get it fixed just don't know where to start and have been too busy on customers vehicles to get anything done on mine.

Yes, DCS has been a tad frustrating. I was very happy with them at first and their adapter plate and motor mounts worked out great. I have used their mounts on many rigs actually. The tach sensor is one of my small issues, but the other was just with their whole conversion kit. I decided to try it out on this truck and none of their specialized coolant hoses or anything fit that was supposed to fit my truck. So I ended up building it all my way and wasting my money. Lesson learned on my part. The other thing that bummed me out was after telling them my tire size, gear ratio, and expected power they recommended the completely wrong clutch. I spent 1k on the clutch from them, that they get from southbend, and it is not hard to slip it in 4th and 5th gear. I called southbend about it and they were awesome and offered me a great deal on a nice dual disk when this one wears out. So in the end there were a few bummers, but if you know what to buy and not to buy from DCS they are good.


Sent from my iPhone using Tapatalk
 
I'll post some up for you tonight. I sold that pick up last year and forgot to change my sig on this forum.


Sent from my iPhone using Tapatalk
 
Here is a video that explains the clutch rod fix I was talking about.

[ame="http://m.youtube.com/watch?v=6C75oQNNows"]http://m.youtube.com/watch?v=6C75oQNNows[/ame]

here is the ebay auction for it.

http://www.ebay.com/itm/251431845147

You can also make your own for about 20 bucks. Below is a pic of my DIY fix. IMHO this is a big part of why so many ZFs have worn out syncros, once the bushing wears out you clutch never full disengages. Which stresses the syncros every time you shift.
 

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so how did you hook up the tach, I've left two messages with dcs and got nothing back.
 
Thank you Mendomotox! I'm gonna order that and try it out! I think a combo of that and the upgraded master and things will be smooth again.

Fummins97,
I'm in the same boat as you. DCS has not been able to give me solid info on how to hook it up. I will bug them about it again soon though. If you hear anything or figure it out before I do please let me know!


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