Hello, I'm new hear. I bought my f150 new in 93 and it has served me well. It's a 4.9 with mazda 5 speed 4x4. The trans is failing and I have not read many good things about this trans. I searched this site and think I can convert it to a zf 5 speed. Is this correct and which flywheel will I use? What other issues are involved with the swap? Thanks Anthony

 

should be pritty much a bolt in deal. use the flywheel you have, same with the clutch(or better yet a new one) than your mastercylinder and lines should all hook up...

 

Is the input spline the same on the light duty M5OD?

I know when I swapped my T-19 to ZF the input shaft was bigger and I had to change the crankshaft pilot bushing and clutch as well as the throwout fork.
(I know that the small block version of the ZF uses a concentric throwout/slave assy.)

 

I thought all ford trannys where 1 inch something like 1/16th or 1/8th with 10 spline....

 

i'm almost 90% positive the input spline count and size are the same on the mazda and ZF (paul... paul... where are you to confirm this????). Keep in mind there are several versions of the ZF... there is a close ratio and a open ratio gearing... the close ratio is for hauling/towing (ie heavy trucks and utility trucks/flatbeds, actual tow truck etc) and the open is for highway driving... Also there are 2 bellhousing patterns. 1 for big block 460 and 7.3 diesel engines and the rest are small block bell housings. you CAN'T swap bell housings because they are integrated into the rest of the case and can't be seperated. However you can swap tail housings if you are ambitious enough to take the inards all apart to make a 2wd zf a 4wd zf or vise versa. ZF's use ATF so buy 6-8qts...? Can't remember how many it takes... and actually if you want to know the truth the ZF S5-47 is better than the ZF S5-42 tranny due to larger internal berings but they were only put in 95-99 f series trucks and are harder to find... Either way the ZF will give you a substantial improvement over the mazda if you take care of it...

To make it as easy as possible for you just get a ZF from a 4x4 300 i6, 302, or 351w and it will be a bolt in... Just remember to change your transfer case fluid if you haven't lately... and lube up the linkages under the truck between your transfer case and the t-case shifter... sometimes these can get rusty and cause problems when you want to shift all the way back into 4x4 low. It's also probably a good time to replace u-joints if they need it...

 

7ish pints

 

Oh, and I would suggest synthetic ATF if you can find/afford it! I used RP Max ATF... but it's kinda pricey... you can find redline and mobil 1 syn atf cheaper... worth the price for the investment though!

 

you might need to chime in on the tranny swap that is on the board now... there is a guy looking at a e40d to c6/c4 swap and i tolt him you know how to fool the e40d computer...

 

Thanks for all the thoughts. Now I just need to find a zf 5 speed for a 4x4. Any ideas? Thanks again Tony

 

Mercon V is synthetic and is recommended by Ford as service lubricant for these transmissions. The input shaft spline count and size are the same as the Mazda, so the existing clutch will work fine. Your Mazda slave cylinder may work, but it would probably be worthwhile to replace it anyway, so just get one for an F250 351/ZF combo matching the year of your truck. The big block and diesel ZFs have different input shafts, but you can't use the case either, so it's no concern.

Don't try to swap a 4x2 ZF to 4x4. It requires you to completely disassemble the transmission and swap the mainshaft. Bearings and such are the same between the S5-42 and -47, the difference is in the tooth count and outer diameter of the gears.

 

The ZF may be hard to find for reasonable price but don't overlook wrecking yards that don't offer self service. I found mine at one of those wrecking yards for a very reasonable price.
The same ZF is used on both the 4.9L and 5.8L trucks.

 

Just throwing this out there, but I was able to get a M5od for $700 shipped to my door with no core charge...remanufactured. The ZF transmission is great, but I didn't want to wait around for the 4x4 version and compete for it. The mazda transmission can get the job done, and they're relatively cheap. They also shift very nice. It would be cool to have the granny low and reverse, but I don't do enough towing to warrant that.

 

Where are you located. My brother has a Zf 5 out of 90 f350 351 truck 4 sale

 

Look for complete pickups. I found mine on a farm, it sat for 3 years, and paid $375 for it. Engine, trans, and Tcase are now in my 94.

 

I'm in Idaho
Tony