Well, I know there have been a million and ten tranny swap posts, and just for the record let it be known that I DID do some searching. Basically my old girl runs like a champ, but could some some upgrading, this is what I'm proposing:

Swap to ZF5
Swap for 4x4
Swap 3.55's for 4.10's

From what I've gathered, in order to do the tranny swap, it's basically bolt on except for the flywheel? Where can I get my hands on one that will work? And for the 4x4 components, what exactly all do I need? I would hate to get the parts together and realize halfway through that I'm missing something. Right now my truck has a 6.9/C6 auto and 3.55 with 2wd and a Banks turbo setup, which is great for the previous owner, but I drive a ways to work, and out here going four-wheeling is a favorite past time, wouldn't mind having a few adventures of my own for a change. So what I'm asking of you guys, is with all your infinite IDI wisdom, bestow on me the list of parts I need to come up with to make this happen. I THINK I know where I can pick up a 4x4 for parts, as far as the transmission and gearing it has is beyond me, if the owner is even willing to sell it. Let me know!

 

Gearing is just swaping the axles out for 4.10s and driveshafts and whatnot. Transmission swap...just go with the ZF5 & buy a new flywheel for it, or find a ZF5 at the junkyard and flywheel to go with it.

As far as the 4x4: That is a BIG project involving a lot of money. You need to swap axles, suspensions and a lot of other various components and would cost a lot of $. People on here have done it, but i personally would buy a 4x4 truck and swap the ZF-5 in it along with the 4.10s...you do realize that if you do 4.10s your mileage will go down? That gear is meant for pulling stuff....

 

I'll second what Aune163rd said, it will be easier, and probably cheaper, to just buy a truck with 4wd a ZF5 then try and build it from a 2wd.
I've done it. It was a pain in the ***, and I need to redo the front suspension because it rides like crap.

 

Buy a 4x4, ZF-5, 4.10 geared truck and sell yours. You will be less money, less time and less aggravation. I am sure there is someone that needs a truck just like yours is currently set up.

 

Yeah, I suppose it might be cheaper, just hard to come by the 6.9's around here. 460, 7.3, 390, 351, 302, they're everywhere but hardly anyone has even heard of the good ol' 6.9. About the gearing thing though, I realize the gas mileage goes down, but I figured with an OD the mileage would remain at least normal while giving me some pull on takeoff and a bit more torque for off-roading. So just as a dumb question, assuming this truck I have seen is a gasser, is it just as much of a chore to do a motor swap? I really love the motor in the old girl, just needs some new gears and something to get me in trouble with out in the hills.

Just as a side note, has anyone else had problems with their EGT gauge on the banks setup? For a while my needle would kinda stick and if I flicked it, the needle would return to normal, but now its just given up. I replaced the end connectors, but to no avail. Basically need to know if it's more likely to be a bad gauge or otherwise.

 

If it's a gasser you will have to do the tranny swap in it along with the motor, different bh pattern, also if it's 3/4 ton I believe you would want to swap front springs on it because the gassers have different springs than our diesels. I would just keep an eye out for a 4x with a blown idi in it and work from there, much easier swap

 

Anyways now that bit is sorted out, I need to know where to get the flywheel for the ZF? To be honest, transmissions confuse to hell out of me, I get the whole drive ratio and stuff, but as far as how they work, nothing. So do I just pull the flywheel off whatever truck the ZF comes from?