I am getting a f250 2x4 with a 7.3 idi and zf5 trans. I want to convert it to 4x4. I wanted to know if the tailshafts are removable on the zf trans and what I have to do to bolt a t-case (BW1356 fwiw)up to it. Thanks

 

There is no removable tail shaft, the main shaft is all one piece so you would need a 4x4 main shaft and a 4x4 rear case section. It's doable, but requires complete disassembly of the transmission plus the expense of the parts so its not really worth the trouble in my opinion.

 

Well, here is my dilemma. I have a 4x4 zf5 trans that came from a 351w and a 2wd zf5 that came from a 7.3. Would I be able to take the 4x4 zf apart and use the parts to make my 2wd one 4x4?

 

Possibly, depending on the year of each transmission. Check the part numbers on ZF's website: http://www.zf.com/na/content/en/impo...t_Catalog.html

 

The zf's in the f450's and some f350hd's were 4x4 units but some people don't know it. ford used the 4x4 tranny for something to bolt the parking brake to on hd trucks with 4 wheel disc and the parking brake off the tranny

 

That is true I saw an E4OD that came out of an F-Series chassis cab truck and it had exactly what you're talking about. As for swapping parts from one ZF to another, like said up above it depends on the year the trans was built and the numbers on the parts list tag on the side of the case. If they match up you should be good to go. Changing the front end over to 4x4 will be a bit more involved. I assume you will be changing it from coils to leaf springs in order to mount up the 4x4 front axle. I know for a fact it can be done because a friend of mine converted an 85 crew cab dually to 4wd. I wish I knew more of the details on the swap but it worked out very well.

 

I wont have to change any of the 4x4 components over since the truck im putting the diesel in is already 4x4. Its only the transmission that needs to be converted

 

I don't know how kosher this idea is but I saw a thread somewhere...
The guy modded his t'case adapter and had it set up behind a 2wheel drive zf.
How? the t'case adapter and the zf shared the same crossmember and he had a spud shaft made from taking a driveshaft yoke. cutting the round part off near the ujoint, took a tranny output shaft cut it off, had part of it stuck up in the severed driveshaft yoke. welded them together, stuck it up in the zf tailshaft and slid the t-case adapter over the other end. hope he had everything mounted solid to keep that shaft running straight.

think it could be bettered by adding a ujoint yoke to the front of your t-case and running it as a divorced but really close to the tranny