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I just finished a trans swap in my 94 2WD, extended cab, XLT with the 3.0 V6. First let me thank the many members who have shared their experiences. They were invaluable in helping me understand what I was up against and in gathering the right parts.
I'm posting this to share what I found when completing the wiring steps necessary to enable the truck to start properly. Ultimately it was pretty simple.
I chose to retain the AT wiring harness and make the necessary modifications.
1) Install the manual transmission ECU.
2) Install the neutral safety switch with the new clutch master cylinder. I bought a Sachs kit (SACHS SPM006), from Rockauto that came with the entire setup. The wiring is already there under the dash near the parking brake. All that's necessary is to remove the jumper Ford installs to bypass the function with the automatic and connect the new switch.
3) Locate the five pin round plug that was connected to the automatic and cut it off.
4) Rewire as follows,
a) Connect the Purple with Orange and the Black with Purple wires to the same color wires on the two pin connector on the manual trans. These are the connections that enable the reverse lights. If your wires are there simple butt connectors are fine. The transmission I bought had the connector on the transmission but the wires were mangled. I sourced new pins from a local electronics store and made a simple harness so that I could retain the factory plug. Note, polarity on these connections is not important as the switch on the transmission is normally open and when you engage reverse the switch just closes, completing the connection and activating the lights.
b) Connect the Red with Light Blue wire to the Pink wire. This connection completes the circuit that enables the start relay to activate. In the automatic this connection is made by the switch on the transmission when the transmission is in Park. Since the automatic is no longer there these wires need to be permanently connected to allow current to flow through the circuit. I just used a butt connector and shrink wrapped the connection to make it water proof. Note, the Red with White wire, which was used to tell the circuit the automatic was in neutral, can just be taped up and left it off.
That's it. Enjoy
I'm posting this to share what I found when completing the wiring steps necessary to enable the truck to start properly. Ultimately it was pretty simple.
I chose to retain the AT wiring harness and make the necessary modifications.
1) Install the manual transmission ECU.
2) Install the neutral safety switch with the new clutch master cylinder. I bought a Sachs kit (SACHS SPM006), from Rockauto that came with the entire setup. The wiring is already there under the dash near the parking brake. All that's necessary is to remove the jumper Ford installs to bypass the function with the automatic and connect the new switch.
3) Locate the five pin round plug that was connected to the automatic and cut it off.
4) Rewire as follows,
a) Connect the Purple with Orange and the Black with Purple wires to the same color wires on the two pin connector on the manual trans. These are the connections that enable the reverse lights. If your wires are there simple butt connectors are fine. The transmission I bought had the connector on the transmission but the wires were mangled. I sourced new pins from a local electronics store and made a simple harness so that I could retain the factory plug. Note, polarity on these connections is not important as the switch on the transmission is normally open and when you engage reverse the switch just closes, completing the connection and activating the lights.
b) Connect the Red with Light Blue wire to the Pink wire. This connection completes the circuit that enables the start relay to activate. In the automatic this connection is made by the switch on the transmission when the transmission is in Park. Since the automatic is no longer there these wires need to be permanently connected to allow current to flow through the circuit. I just used a butt connector and shrink wrapped the connection to make it water proof. Note, the Red with White wire, which was used to tell the circuit the automatic was in neutral, can just be taped up and left it off.
That's it. Enjoy
