2.9 clutch conversion to 4.0

[vonD1025]

Ford 2.9 Converted To 4.0 Clutch - The Ranger Station

Story by NoV8? Why Drive? The 2.9 is a near bullet proof 4×4 engine, but it suffers from a very small 8-7/8″ clutch and flywheel that becomes a problem when running large tires and in steep hill or rock … Continued

www.therangerstation.com

 

[vonD1025]

Ok question on here. When it says “1997 or earlier 4.0 manual starter (Auto will not fit)” . What does it mean exactly?

 

[vonD1025]

I swapped engines and transmission from automatic to manual already but there are old parts of the transmission from the auto still there.

 

[4x4prepper]

Ok question on here. When it says “1997 or earlier 4.0 manual starter (Auto will not fit)” . What does it mean exactly?

On many vehicles the starters for manual transmissions differ from automatic starters because the teeth on the flex plate (automatic) and flywheel (manual) are in different positions relative to the back of the engine and the diameter. I know on the 2.8L there is a difference because I broke a starter when O'Reilly's gave me the wrong one and I proved it by measuring it in the store in front of the manager. Same thing when they were selling the defective Ford starter relays that were nuking starters and batteries by sticking on. I had to go and prove it with a multi-meter and article from a FSB Bronco website.

 

[lil_Blue_Ford]

Yeah, it’s a fit issue. I did a 4.0 clutch in my choptop and had to use the 4.0 manual starter rather than the 2.9 starter. 98 and up 4.0 starters were a different size and requires a different shim plate between the engine and trans. Not sure if the plates can be interchanged to use a dif starter but then you’re making getting parts a little more complicated. I have actually started little books with part numbers and such on what I’ve modded to make getting parts easier.