Planning to swap from automatic to manual transmission

[Convict1997]

This is just in the planning stages right now, but any input would be helpful. The automatic in my 2002 XLS 2wd 4 door is acting up. Instead of going with a new/rebuilt and possibly ending up with the same problems, I'd prefer to swap in a 5spd. I contacted my local dealer and they gave me a list of things that I would need. This may not be all inclusive as they said it was off the top of their head:

slave cylinder
master cylinder
pcm and wiring harness
transmission
drive shaft ? possibly the same
bell housing ? possibly the same
frame cross member? possibly the same
clutch/brake pedal assembly
dash brace ? brace for what?
clutch and flywheel

Ideally, I'd like to find a wrecked donor truck to pull these parts from, but I don't think that's going to happen given the limited number of 2002 4 doors with a manual transmission.

some questions I have

1 what model manual transmission did the 2002 XLS four door use?

2 can I pull the transmission/bell housing/clutch slave & master cylinder from a Ranger?

3 would I be better off getting things like the slave cylinder, master cylinder, and flywheel new?

4 they said I'd need to replace the PCM and wiring harness. I've heard I could just reflash the PCM that's already in there. Anyone know for sure?

5 is there anywhere I can go online to check if any of these parts interchange between other vehicles such as the ranger or the sport trac?

 

[imp]

If you go with all Explorer parts, it will ease the job immensely. My first question is: Did they offer manual trans. in the 3rd. gen. at all? I understood 2001 was the last year, but I could be wrong. Obviously, given the size difference between 2nd. and 3rd. gen, things like crossmembers and driveshafts will be a problem, if using pre-2002 parts.
slave cylinder : This is part of an ass'y. within the bellhousing, which is no longer a removable section (the hsg.). The slave and throw-out brng. are part of an assembly surrounding the trans. input shaft. So, if you obtain a used 5-speed, it will likely already have the slave mounted on it.
master cylinder : Needed, along with the clutch pedal ass'y. under the dash. Again, if no '02 Exp. came with this, you will have to adapt earlier. Working under dashboard NO FUN!
pcm and wiring harness : Again, if no '02w/manual, earlier PCM will cause big headaches with anti-theft system. I would personally try driving the newly installed 5-speed manual using the OLD PCM first. You would have to live with a "check eng." light.
transmission : Get one out of an Explorer. 4X4 or 2X4?? Output shafts are different.
drive shaft ? possibly the same : Possibly, but doubtful. The auto. trans is proly longer than the manuals.
bell housing ? possibly the same : No! Bellhousing is part of the trans., either auto or manual, not removable!
frame cross member? possibly the same : See above.
clutch/brake pedal assembly : ditto.
dash brace ? brace for what? : Think they mean the support which suspends the brake & clutch pedals; different w/manual trans.
clutch and flywheel Obviously necessary.

some questions I have

1 what model manual transmission did the 2002 XLS four door use? : M5OD, built by Mazda.

2 can I pull the transmission/bell housing/clutch slave & master cylinder from a Ranger? : Yes, but will the bellhousing bolt pattern match your engine's pattern? Or, was same engine as yours used in Ranger?

3 would I be better off getting things like the slave cylinder, master cylinder, and flywheel new? Yes, but pretty costly. The cyls. are throw-away, no seal kits avail., so develop a leak in couple months, how will you like pulling out the trans. to get at the leaker?? Flywheel, inspect carefully used part.

4 they said I'd need to replace the PCM and wiring harness. I've heard I could just reflash the PCM that's already in there. Anyone know for sure? : As far as making the engine run, current PCM could care less where the power goes. Only problem is it's looking for auto. trans. inputs which will be gone (fluid temp, shaft speeds, etc. I am pretty certain the eng. would run OK with the transmission electrical connections simply disconnected. Why mess with the harness? Big can of worms there. OTOH, you could use a PCM and it's harness from an earlier Explorer not having the Passive Anti-theft System gimmick in the key. YOU would have to be the electrician genius who connected the necessary sensors, fuel pump setup, clutch & brake pedal safety switches, neutral start, etc. The earlier harness has mucho different connectors for most of the eng. sensors, and the sensors on your current engine won't fit them.

5 is there anywhere I can go online to check if any of these parts interchange between other vehicles such as the ranger or the sport trac?: Wish I had an answer, sorry, I do not. If you go ahead with this project, PLEASE keep us informed. It is something I am aiming to try too! imp

 

[Convict1997]

I know the Rangers came with the 4.0 SOHC starting in 2001. I think the 2002 or 2003 sports only came with the SOHC. Since it's the same motor I wouldn't think there would be any problem with getting it to bolt up. Also, finding a 4 door with the manual transmission isn't going to be as easy as a 2 door or a Ranger. Now, I HAVE been able to locate a few online but, when pulling parts like this, I'd prefer to be able to see what I'm working with. Also, most places will offer some kind of warranty and, if it comes to that, I don't want to be waiting for the mail man to deliver my replacement.

2002 was the first year of the 3rd gen explorer and the last year of the manual transmission. As far as I know, it was only available on the XLS models. I've got the original window sticker from my vehicle and, wouldn't you know it, the only option installed on this truck WAS the automatic transmission.

As far as the PCM, when this goes down, I'll give it a shot with using the current one just to get it running. I don't like the idea of a constant check engine light, though. Won't the truck be stuck in limp home mode until I get that figured out or is that only with the emissions codes? If I do replace the PCM, it will be out of the same year w/manual transmission. I don't want to have to try to rewire the whole thing to work with a different year's harness.

 

[imp]

My understanding of the limp home mode is that it takes over as running strategy only when the loss of a sensor input partially diasbles the PCM's ability to continue running using it's normal program.

However, I lack enough experience with EEC-V to say that lack of transmission feedbacks (shaft speed sensors, fluid temp. sensor, digital switch position, etc.) would not adversely affect engine running qualities.

In the early 90s, EEC-IV used different PCM for auto. trans. vs. manual, but even so, when I built several vehicles as conversions from carburetted to EFI ('69 Mustang Mach I 351W, '79 Ranchero 5.0L HO, '95 Mustang 5.0L HO in 86 Toyota 4X4 pickup, I used the automatic specified PCM with 5-speed manuals in each case with perfectly acceptable results. imp

 

[Brian T Nickless]

M5od

I have a 5R55e to M5OD swap starting tomorrow D) and , just for peace of mind, I went with new throw-out bearing, new clutch slave cylinder, pilot bushing, re-surfaced flywheel ( and possibly some other things ) I just didn't want to be tearing the whole thing out in a year due to leaks/ problems. Also planning to go with Mobil 1 ATF . Again, mostly for peace of mind. Brian

 

[briwayjones]

You can just re-flash the PCM with a tune set for a manual transmission.

 

[Convict1997]

I'll be interested to see how this turns out. I eventually abandoned the project as the explorer was my daily driver and I couldn't afford to be without it if something didn't go right. I chose the easy route, sold he explorer, and bought a car with a manual transmission.

 

[poory]

Hi I have a 1999 explorer and thinking of changing automatic transmission to manual gear box. Has anyone got a list of things required and a plan of how to approach suck a task this would be great.

 

[Jacob Kline]

OK I can see that this thread is super old, but I'm just mentioning for posterity that I own a 5-speed manual 2002 Sport Trac XLS. Wikipedia shows standard transmission was optional for that year, can't remember if that was the first year it was not standard. (LOL.) Maybe this'll inform some future explorer.

 

[boominXplorer]

The sport trac and 2002 4dr use a different but same model transmission that can't interchanged. I actually have a 2002 4dr and a 2003 2dr manual trans on the shelf in storage.