Will it fit?

[Gavin.b33]

Hello, I have a 2003 4.0 4x4 with an auto in currently and have a 1995 4.0 4x4 5speed that I want to put in it. I’ve read that it should be able to work provided the bolting pattern is the same. Could I get a definitive answer on this as I am about to order all the parts for it?

I am also new to manuals and everything that is required during the swapping process. A good list of what I would need for it would be extremely helpful.

Thanks,
Gavin

 

[dvdswan]

Welcome to the site. Check out the Tech Library section.

 

[Curious Hound]

Not clear about what you want to do. Are you talking about a complete engine and transmission swap? Or do you just want to put the manual transmission in place of the automatic? If just swapping transmissions, Both engines are 4.0l. So the transmission bellhousing bolt patterns are the same. You would need to get the flywheel and clutch to go with the manual. You will also need the whole clutch pedal and bracket assembly plus the master cylinder. I think the thin plate between the engine and transmission might be different. So make sure you use the one for the manual transmission. I think that has something to do with positioning the starter motor. And you might need the starter motor that goes with the manual because sometimes the nose of the starter is longer or shorter. Then minor changes to the wiring because now you have a safety switch on the clutch pedal instead of the Ned on the auto transmission.

That’s all I can think of at the moment.

 

[Snoranger]

The pedals may swap, I’m not sure I’ve never manual swapped an ‘03.
The flywheel from the ‘95 won’t work... it’s a 6 bolt flywheel. The ‘04 is an 8 bolt.
The trans bolt pattern is slightly different... you won’t use the top right bolt.

 

[Gavin.b33]

Not clear about what you want to do. Are you talking about a complete engine and transmission swap? Or do you just want to put the manual transmission in place of the automatic? If just swapping transmissions, Both engines are 4.0l. So the transmission bellhousing bolt patterns are the same. You would need to get the flywheel and clutch to go with the manual. You will also need the whole clutch pedal and bracket assembly plus the master cylinder. I think the thin plate between the engine and transmission might be different. So make sure you use the one for the manual transmission. I think that has something to do with positioning the starter motor. And you might need the starter motor that goes with the manual because sometimes the nose of the starter is longer or shorter. Then minor changes to the wiring because now you have a safety switch on the clutch pedal instead of the Ned on the auto transmission.

That’s all I can think of at the moment.

correct, just swapping the transmissions. I was looking at the flywheel for the 1995 manual and the flywheel has 6 bolts in the center but when I look at the flex plate for my 2003 is has 8 bolts in the center. Will this be a problem fitting in the 2003 motor or will it work as long as I get everything 1995 for the transmission?

 

[Gavin.b33]

The pedals may swap, I’m not sure I’ve never manual swapped an ‘03.
The flywheel from the ‘95 won’t work... it’s a 6 bolt flywheel. The ‘04 is an 8 bolt.
The trans bolt pattern is slightly different... you won’t use the top right bolt.

so would I be wanting to buy the 8 bolt flywheel?

 

[Shran]

You need the 8 bolt flywheel for a newer truck.

Pedals, I think 1998 and newer will work, I am not totally sure about 95-97, it's a "maybe"

 

[Gavin.b33]

You need the 8 bolt flywheel for a newer truck.

Pedals, I think 1998 and newer will work, I am not totally sure about 95-97, it's a "maybe"

I have the pedals that came with the 95 so I should be good on that. Now, if I got the 8 bolt flywheel, would it be able to fit on a clutch for a 95? If not, would I have to get a clutch for my 2003? And would that newer clutch fit in the bell housing of the 95 transmission?

 

[Shran]

I think I would recommend buying a clutch to match the flywheel... so if you get a flywheel for an '03, get a clutch that fits the '03 as well. RockAuto seems to indicate that 91-97 (maybe up to 2000) clutches are different than 98 up.

The newer clutch will fit in the bellhousing just fine, it's probably just a matter of how it attaches to the flywheel. Bolts in different spots or something, I don't know for sure.

 

[don4331]

The clutch, itself, is same between, '90 and '11, so that swaps easy.

Ideally, you want both the manual transmission wiring and the manual transmission GEM from an '03 (and that might require the '03 instrument panel and PATS (from above glove box/behind airbag). Ford got sophisticated about linking all the components together - GEM, PATS and Odometer. If you don't swap all the components, you will have a check engine light on continuously.

 

[Shran]

Haha, I guess I meant the pressure plate itself, not the clutch disc.

 

[don4331]

Yes, pressure plate and flywheel need to match. Clutch friction dis is same.