OK guys, I need help and fast! I'm getting a new tranny this Saturday and I'd like to get it put in Sunday. I need know step by step what to do, starting with taking the ZF5 out and what to do first to putting the T-19 in. Pictures will help. It's going to be a T-19 I'm putting in. Yes I know. Y'all don't need to say anything about the new tranny. I know they are slow. I'm sure at least one of y'all has done this. I've never done this before.

 

First off, do you know if you have a dual mass or a single mass flywheel? The ZF came from the factory with the dual mass. It will not work well with the t19. You will need the clutch disc for the T19, as it has a smaller input shaft than the zf. Did you get the bell housing for the T19? The bell is part of the zf and will not seperate from it, so you need the 6.9 bell housing. The master and slave cylinders from the zf will work with the t19. The transmission cross member is a little different, but it can be made to work.

 

For $400 I'm getting the tranny, clutch, bell, and flywheel or pressure plate, along with an extra slave cylinder. I already have both on my truck. I hope the drive shaft will fit. I'm thinking it should. The truck had a T-19 in it before, so it should still fit OK, I'm hoping. The truck is in the garage and ready for the swap.

 

iirc the drive shaft will be shorter becase the zf5 is longer

 

To swap trannys- remove the rubber boot from shifting lever. remove 2 bolts that hold lever to shifting tower, remover 6 bolts that holt tower to tranny, then lift tower straight up.
Under truck- remove drive shaft, remove 6 bolts that hold tranny to motor, remove slave cylinder by prying towords drivers side, it is held on with a spring clip, remove 2 nuts on tranny to cross member mount, place tranny jack under tranny and secure, lift tranny with jack and remove cross member, slowly lower tranny jack whil wiggling tranny side to side and pulling back, when tranny is clear you can start on removing the pressure plate, If you have a dual mass fw, the pressure plate will be held on with 8 bolts, the single mass conversion will have 8 bolts also. when the bolts are removed the pp and clutch disc will be free to remove. Remove the bolts that hold the flywheel to crank,be careful the fw is heavy and hard to handle under the truck. It will set on a lip on the crank so it won't fall off, but it won't take much to pull it off.
Now you are ready to install the new stuff, first is fly wheel, set fw on lip and turn untill all holes line up, use thread sealand on fly wheel bolts, the holes are staggered so it will only fit one way, If the old fw was a dual mass, the bolts are longer if I remember right, and will be to long so get the bolts with the T19 tranny. If old fw is single mass they will work with new fw. clutch and PP is next, be sure to get the clutch plate insalled the right way Hub pointing away from engine, it helps to have an allinement shaft to get the clitch in right spot. The T19 pressure plate is held on with 6 bolts. This is why the fw needs to be changed. Tranny is next. You can remove the T19 from the bell or leave it together to install. It is a little easier to separate the 2 and mount the bell first. I usually have a couple of long bolts with the heads cut off threaded into 2 holes in the engine where the bell bolts go the help line the tranny right, when the bell isflush remove the 2 long bolts and put the original bolts back in. Mount up tranny, install cross member, Install slave, install drive shaft, Install shift lever, install rubber boot and you are done. I woul be sure to use a new thow out and pilot bearing when installing do you don't want to do this all again because one of these fails.
After all of this I have to ask, Why are you removing the ZF?

 

The ZF5 is completely SHOT. Here is a list of just a few things it does: It pops out of gear sometimes, you can't shift or downshift without it grinding, When the truck is idling, it sounds like the gears are grinding constantly, when driving it sounds like its grinding constantly, it leaks everywhere, and worst of all, it came out of a 93 truck. I don't have a place to plug in the speedo cable. Basically, it sounds like it's about to self-destruct itself. I have to do something. I can't find any ZF5s anywhere, let alone in my price range.

 

Ok guys, I got the tranny and the whole clutch assembly. Got the ZF5 out today and cleaned up the new tranny. Got to get a few things before I put the T19 back in. Here's some pics.

 

Awesome! I hope your swap goes well, take pics of the tricky parts

 

Pictures would be great.

Chet

 

I just put my own T-19 back in today.

It's a b!tch of a job. You're really going to have to wrestle with it.

Also, make sure the input shaft bearing on that T-19 is good to go before you throw it back in. They seem to be the most common T-19 failure.

Good luck
-Matt

 

Both of those bearings are going to be replaced. The one I pulled of the truck was badly wore. Thanks to my dad's help, I have gotten this far. He has swapped several trannies before. I'll take more pics today. The back of the engine is a little oily. I think I need a new seal foe that rear plate. Ditching that freaking CDR will help. I found out that the PO modified the tranny cross member. It says C6 on it, so I'm assuming it was for a C6 auto. The dingbat must have gouged out the slots to fit the ZF5 with a cutting torch. I'll probably have to get another.

 

Do you have a 6.9 flywheel? The T-19 & ZF use different flywheels. IIRC you can use a XF w/ T-19 flywheel but something isn't quite right and it makes all kinds of noise. Not sure about going the other way around.

Drivelines should be close enough to work. Crossmember should also be close enough.

 

The last pic shows the two different clutch/flywheel assemblies. The one on the right is for the ZF5. The one on the left is for the T19.

 

Ok, didn't see that, thought that was just the clutch.

 

Yep, the clutch assembly for the T19 is smaller than the one for the ZF5. I guess the 7.3L had to have a bigger clutch.