ZF install complete, pictures

rowdyredneck · #1 (**permalink**) 05-28-2008, 11:32 PM

I just finished converting my '84 F-250 4x4 from a Borg-Warner T-19 four speed to a ZF five speed. This truck originally had a 351W with a C6 auto when I bought it. I drove it for a few years, then stripped it to the frame and completely restored it. In the process I converted it to a 460 with a four speed and installed a 2 1/2" suspension lift along with many numerous upgrades. I had two main goals with this conversion; my main goal was to improve fuel economy but I also wanted it to look as clean and stock as possible, so I went to great lengths to that effect.
First, my original shifter layout:

I was unsure of floor clearance problems, so I gutted the interior and removed the floor pan. On the left is my original pan, on the right is the taller ZF pan which also lacks a shifter hole for the transfer case.

Here's both transmissions together. On the left is my original T-19, on the right is the ZF I pulled from the '88 F-250 donor truck. The ZF uses a larger diameter input shaft so the T-19 clutch won't fit. The ZF also uses a larger disc and pressure plate, so the bolt pattern is also different which required the flywheel from the donor truck.

Here's where my attention to detail comes into play. That big, straight five speed shifter just looked out of place so I wanted to make my own. The ZF uses two bolts to fasten the shifter lever to the transmission. On the top is the ZF shifter, middle my old T-19 shifter, and on the bottom was my solution: a piece of 5/8" stress proof steel with a 3/8" x 3/4 flat steel for the lower end.

Stress proof rod is stiffer and harder than mild steel, so heating is required to properly bend it. After careful measuring and comparing I made two bends to match the contour of my old shifter.

Here's the end of the completed shifter after I welded it to the rod and painted it. I used a cutoff saw to grind a groove into the middle so it mated perfectly with the shifter stub on the ZF.

ZF trucks use different drop brackets for the crossmember, they curve toward the rear to move the crossmember back. I had the brackets from the donor truck, but I still had to drill a single hole in each side of the frame for the lower bolts.

Everything is finally in place on the bottom side. A quick coat of spray paint was used to match the frame color. My original New Process 208 transfer case bolted right up to the ZF and both driveshafts were the correct length.

Finally its coming together on the top side. My original floor pan fit with a few taps of the hammer around the top right corner of the transfer case shifter hole. The transfer case shifter bolted directly to the ZF without any modifications to the lever or linkage. My custom built shifter is also installed.

The interior is all back together. Everything looks completely stock and I'm willing to bet nobody can tell there's a five speed in there unless they try the shifter in all the positions or look under the truck.

Finally! All thats left is a good washing and a fresh coat of wax and she's ready to hit the street.

I absolutely LOVE the results of this conversion. Before my cruising RPM at 60 mph was around 2300, now its down to about 1750. At 55 mph I'm running a leisurely 1600 RPM. In order to reach my previous 2300 RPM cruise speed I have to run her up to 75 mph! Its quieter inside the cab as well. Gas mileage results aren't in yet, but I'm expecting a significant improvement over the 8 miles per gallon I'm used to.
In case anyone is wondering, this is what the truck looked like about ten years ago before I restored it:

srercrcr · #2 (**permalink**) 05-28-2008, 11:57 PM

Very nice work.
Alot of folks think that if you have a low-rpm top gear you can't get power or pull.
Not so.....just downshift! You've got the pick of four other gears.
I pulled a travel trailer with my 4OD by just using third, which is 1:1. I presume your fourth gear is 1:1. Again, congrats. You exemplify a Ford Truck Enthusiast.

86Stepside · #3 (**permalink**) 05-29-2008, 12:15 AM

I have also just completed this conversion a little over a week ago on the 86 4x4. I found my zf last fall, but didnt get a chance to put it in till now. I ended up using the BW1356 that was with the trans, so I had to cut a hole in the floor. So far I think I gained about 2-3 mpg, but over the weekend I did a tune up so I hope I'll get more. The best part is I only paid 65 bucks for the zf, 50 for the T-case, and about 150 for other misc parts I needed.

ArdWrknTrk · #4 (**permalink**) 05-29-2008, 06:08 AM

Wow! That is one clean truck.
And a very 'sano' installation.

Thanks for sharing your detail pics.

BTW, is there a reason for using the 4speed knob?

rowdyredneck · #5 (**permalink**) 05-29-2008, 06:58 AM

Thanks.

I love this truck. Black is impossible to keep clean, but when its all shined up it turns heads wherever it goes. I'm a big fan of the "sleeper" look and making things appear completely stock, so that's why I reused my original shifter knob. I have about $500 in the conversion; $250 for the transmission, $25 for the flywheel, and $205 for the clutch kit plus a few other small parts.

Sycostang67 · #6 (**permalink**) 05-29-2008, 05:31 PM

That looks awesome, I am very envious of that shifter. I love the look of the older curved shifter handles. I actually paid attention today, and noticed that at 60 mph i'm turning about 1900rpm. I have the 4:10 gears where I think you said you had the 3:55's.

jay54f100 · #7 (**permalink**) 12-11-2008, 12:51 AM

can you hook up a np 203 to the zf?

Oscar Meier · #8 (**permalink**) 12-12-2008, 02:36 PM

Excellent - My '85 4x4 has the NP 435 and I would love to have the ZF. Your post is inspirational.

nflfreak43 · #9 (**permalink**) 12-12-2008, 03:34 PM

dude i just now was able to be on my home computer and see these pictures. What can i say other than WOW!!!!! Nice truck. that was a great swap. and you know something i just noticed. Your truck is dueled. dont know what the exhaust set up is but ya know. Id like to hear bout it. and also what kind of lift did you put on there and who'd you go to for parts for the resto.

Stevoh · #10 (**permalink**) 12-12-2008, 07:33 PM

Wow sweet conversion man. I have been thinking of converting my 460+c6 trans to a manual. Where did you get the transmission and the other associated parts??

Also what other parts would one need to do this besides: ZF gear box, cross member, clutch+flywheel, clutch fork, clutch pedal, clutch master cylinder( I am assuming it requires one), clutch line, shifter, and floor cover? Are ZF clutches even hydralic? The bell housing just bolts up fine to a 460?

Do I need to get a new drive shaft or the cone thing that bolts to the transmission?

uncle.stosh · #11 (**permalink**) 12-12-2008, 07:40 PM

You will need the hard to find big block ZF. The bellhousings are integrated and different than the small block.

ScottInTexas · #12 (**permalink**) 12-12-2008, 09:40 PM

Excellent work! I'm always envious of people that have the talent and patience to do that kind of work. Move next door, I'll by the beer. My 84 is ready for more work!

Sycostang67 · #13 (**permalink**) 12-13-2008, 12:08 AM

Quote:

Originally Posted by Stevoh

Also what other parts would one need to do this besides: ZF gear box, cross member, clutch+flywheel, clutch fork, clutch pedal, clutch master cylinder( I am assuming it requires one), clutch line, shifter, and floor cover? Are ZF clutches even hydralic? The bell housing just bolts up fine to a 460?

Do I need to get a new drive shaft or the cone thing that bolts to the transmission?

The clutch is hydraulic, you will need the slave cylinder for the tranny, and a clutch master for the year of your truck. The hose will connect the newer slave to the older CMC. You will need the entire pedal assembly from an 84-86 truck with the hydro clutch. You can swap the floor pan or cut the one you have. Can't tell you for sure on the DS as I converted a 4wd. I dont know if the 2wd versions of the C6 and ZF used a slip yoke or a fixed yoke.

When I did the conversion I had a complete truck that was the same body style as mine. I used the newer t-case that was attached to the ZF and had to take the DS and the yoke from the rear axle as the newer DS used larger u-joints. My old NP208 case had a fixed yoke output while the newer BW1356 used a slip joint.

Stevoh · #14 (**permalink**) 12-13-2008, 02:45 AM

Interesting. I forgot about the slave cylinder. I wonder how much all the parts for the swap would be.

It seems BBF ZFs are hard to come by?

Also I forgot to ask, how strong are the ZFs? I know the general consensus is that the C6 is a strong reliable trans, but it only has 3 gears and my truck has a 4.11 rear gear. Are the ZFs good at towing? That is primarily what my dually is for. I think driving around in a huge manual truck would be fun too.

Sycostang67 · #15 (**permalink**) 12-13-2008, 10:53 AM

I see plenty of BBF trucks with the ZF, most of them are still on the road though. I bought a complete running parts truck for $700 because it had a bad WP, torn firewall and no title. With the money I made selling other parts from the truck, the swap only cost me about $50.

I swapped out my C6 for the ZF and never looked back. My truck rarely leaves my yard without a trailer attached. I can take hills much faster with the ZF and not worry about overheating the tranny, and my mileage went up 4.5mpg. I also have 4:10 gears and was afraid to take my truck over 70mph with the C6, now I can hit 85+ without breaking a sweat.