out with auto … in with manual

@ 459,719.5km

Replaced the automatic transmission with a manual transmission.
The mechanical part is pretty straight forward, several forum threads can be found about this. e.g. Auto to Manual Converstion …
We had a donor truck sitting right outside the shop and could pull whatever we needed.
We cut the floor hump a bit small on the passenger side, should be cut right down to the floor. Had to apply some craftsmanship to form the gap close.

The electrical part was a bit more of a challenge, as most conversion write-ups are based on ’99 to ’01 trucks. My truck is an ’02 and Ford changed the electrical system significantly.
We used the manual wiring harness out of the donor truck and merged the 4×4 indicator switch and into the harness in my truck. Also hooked up the reverse lights switch into the original harness.
I found the instructions here: 02 and 03 ZF

To “make” the automatic PCM a manual PCM, I installed 17 position hydra chip. By installing manual software onto the chip, the PCM software gets overwritten.