ZF5 swap problems
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Laughing Gas
Joined: Sep 2007
Posts: 869
Likes: 5
From: Near Shenandoah Valley
ZF5 swap problems
Subject truck is the '83 in signature. I have been working on it off and on for maybe two weeks.
'83 6.9 diesel using existing flywheel single mass, clutch disc RCF 2000 Napa, existing drive shaft used Precision 448 u joint. Bled slave cyl. And feels like good pedal. Also modified donor '93 trans crossmember . There is play between clutch disc and flywheel and/or pressure plate. Slave cyl. Has 1/2" travel just like my '89 and '96.
Before starting this swap a guy that did it earlier said he only had issue with crossmember, now he says he had to modify the clutch pedal rod to take up more slack and use a return spring. Suggestion? Experience?
'83 6.9 diesel using existing flywheel single mass, clutch disc RCF 2000 Napa, existing drive shaft used Precision 448 u joint. Bled slave cyl. And feels like good pedal. Also modified donor '93 trans crossmember . There is play between clutch disc and flywheel and/or pressure plate. Slave cyl. Has 1/2" travel just like my '89 and '96.
Before starting this swap a guy that did it earlier said he only had issue with crossmember, now he says he had to modify the clutch pedal rod to take up more slack and use a return spring. Suggestion? Experience?
Postmaster
Joined: Aug 2010
Posts: 2,554
Likes: 7
From: Northern Arizona
I was under the impression (was told by members here) that the stock, SMF flywheel for a 6.9 T19 truck would work with the ZF as long as the '87 6.9 ZF truck clutch disc and pressure plate were used. Is this not the case? From what you are saying, the answer is NO.
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Laughing Gas
Joined: Sep 2007
Posts: 869
Likes: 5
From: Near Shenandoah Valley
I'm not sure about the "offset" issue. I'm leaving in a few minutes to go to parts store to see what is there. Like I said here earlier and on a couple threads trying to attract attention is, it's not what a lot of people told me. I read some older threads about the trucks having the option in '87 of 5 speed, but many people said " just change the clutch disc." Both on here and eye ball to eye ball. I'm absolutely an idiot for not measuring the diameter of the ZF5 shaft/ snout FIRST. the spline shaft had clearance but the snout around the shaft did not. The length seems good ( measures over all within about an 1/8"), the clutch disc the same thickness, .340 - problem was the clearance through the pressure plate on the '83. I will really look the set up over good before walking out of the store.
What would be a tell tell sign it does not have the right " offset"?
I was trying to avoid the purchase of new flywheel, the last set up I bought for the '89 to go from DM to SM cost over $ 600.00 total, flywheel, clutch/press. plate etc.
What would be a tell tell sign it does not have the right " offset"?
I was trying to avoid the purchase of new flywheel, the last set up I bought for the '89 to go from DM to SM cost over $ 600.00 total, flywheel, clutch/press. plate etc.
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Laughing Gas
Joined: Sep 2007
Posts: 869
Likes: 5
From: Near Shenandoah Valley
I typed up my earlier response before my second cup of joe. The offset I assume is the thickness of flywheel and the depth it sits off crank, and therefor the over all distance toward the trans/spline shaft? Can any of this distance be corrected with longer/shorter throw out bearing? If available?
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