ZF tranny ques'

[studlybilly]

Hello all, I have a slight dilemma,
I put a 1989 302 in my samurai and chose a 1990 ZF out of a F250, as my tranny. The problem is its 2wd ( Im currently running stock divorced t case). I want to know that if I change the rear housing to a 4wd housing and put a different tailshaft in it can it be converted to a 4wd tranny in order to use a mated transfer case. Also, my front axle is passenger side pig, so the transfer case must be as well, I would like to use a Jeep D300 transfer case. A myth proposed to me ( considering it a myth since I've never heard of it and had no second opinions) is that the transfer case will bolt right up to ford trannies that ran NP transfer cases ( given they bolt up to GM trannies which use NP transfer case) with the only addition being a rear output shaft which will convert over to the d300 splines...Can someone please help me out here?

Thanks a lot.
Billy

[RTM]

You can buy a rear 4x4 cover or tail housing and you will need a new output shaft. The cost of these two items will run right $500 plus any labor to switch them unless you do it your self. Do a search for ZF parts and you will find a break down drawing of the trans and the different part numbers of the parts needed. The rear I think has gone up in price since the last time I looked.

I would provide the info for you but I am at work right now and I haven't reloaded my favorites yet after the reformatting of my computer this weekend.

[studlybilly]

Thank you for your reply, Ya Im going to get a rear housing from a local tranny rebuild shop, they have a used one lying around, as for the trailshaft I will either use a kit from AA to bolt a D300 transfer case, or if the bolt up case myth is true then all I'll need is a modified output shaft...But thanks for clearing up the ability to make it a 4wd trans...now if someone would tell me if the myth is true or not..

[Racerguy]

One thing to remember is that on a ZF the rear case isnt just a bolt on piece like on most transmissions. All the guts of the transmission fit into the rear case half and then the front half bolts onto it.

[studlybilly]

dang, thats news to me, so basically the area that the rear housing covers needs to be replaced with 4wd tranny stuff?

[Racerguy]

The output shaft and the rear case half are different and would need to be replaced.
Not the best picture but take a look at http://www.drivetrain.com/zf47.html
The back case halves are part #2 in the picture.
When you assemble the transmission all the internal parts sit in part #2 and then you lower the front case (part #1) onto that.

[Freight Train]

You need the mainshaft for 4X4, cost is around 445.00, and the new rear case will run around 200.00

Labor will be high to replace the mainshaft as all the gears and syncro's have to be removed from your 4X2 shaft and installed on the new one.

To round up the parts list, (providing the rest of the tranny's guts are ok), you'll need 2 tubes of anerobic sealer, 10.00ea., new front and rear seals, 12 for the front and 10 or so for the rear. 3 shift finger detent plugs, 4-5 bucks each. and probably new rear bearings for the mainshaft and countershaft. The tranny shop will opt for this rather than try to get the races out of the old rear case, bearings are around 50 dollars each. Last but not least, a shift rail roller bearing, (The old one will never come out), that's another 40-50 bucks.

All and all, this is about a 1400.00 job in a tranny shop.

I would probably just hunt for another one, then sell the one you have to make up the cost of converting to a married case in your truck. I can take these apart in my sleep, and I don't even think I would try converting it to 4X4.

[troposcatter]

Ok Thats what I wanted to know, it lools as if it could work with a long wheelbase and a divorced Xfer case but it is obvious that it would be cheaper to find a five speed 4X4 tranny