Iv been hunting down a good zf5 to swap into my 91 7.3 and finally found one. Was able to buy the trans, single mass flywheel, pressure plate, used clutch, clutch fork, crossmember, steering wheel, pedal assembly, and shifter. The trans has the slave cylinder attached but the line to it was cut so Ill need a new one. Before I start the swap I'm trying to compile a full list of things I still need. I remember reading that a new master cylinder is needed but not sure why it would change. What sensors will I need for the spedo to operate, I noticed the guy just cut all the plugs and left a few inches of wire on them. Are the plugs/sensors something I can connect to the harness from the auto trans? I will be having the driveshaft custom built or modified from the existing 2 piece shaft.The engine was in a previous truck mated to a zf5 with a dual mass so itl be happy to have a manual behind it again.
The automatic was installed less than 10,000 miles ago as a re manufactured unit from Ford but its having electrical input problems and acting weird. It works great but the inputs are making it think the brakes are applied and unlocking the trans. Itll be for sale if your i the New JErsey/PA area and want it Thanks guys

 

Your 91 should have the mechanical driven speedo, so the tranny needs to be from a 91 or older truck, as the cable for the speedo is driven by a gear in the out put shaft of the tranny, or the transfer case if a 4X4. In the 92 model year Ford switched to an electrical speedo driven by the sensor in the rear axle. So if the ZF 5 came from a 92 or newer, it won't have the port for the speedo gear in the tail housing. The 4X4 trannys don't have the speedo ports as that port is in the transfer case.
Your brake master cylinder will work with the ZF, but you will need the clutch master cylinder.
The only sensors on the ZF are the back up light switch, and the speedo drive on the 91 and earlier trannys.

 

You need the transsmission wireing harnas it will hook every thing up, a clutch safty switch. I just bought a junk yard drive shaft for mine.

 

Im not sure what year the trans is. THe man I bought it from just said its the same body style as my 91 so that could be from what 87-91? That means Im in good shape. Does that mean the speedo gear has the same tooth count in the auto and manual?
Red454sedwick- What is in the transmission wiring harness? Wouldn't it just be the neutral safety switch and reverse lights?
Id get a junkyard shaft, but no yards by me have that model truck in longbed and extended cab 2wd

 

Yes its just four or five wires, but If you find a junkyard one, every thing will plug in.
If your truck has cruse control there will be two wires going to the speed sensor.

 

I do have Cruise control. I was looking on autozone's website for a new clutch. THe one i found id PN# NU314411L, is this correct for the single mass? I believe it is but its only the 11". I want the 12" but cant find one, any ideas?

 

I got a single mass kit from Autozone. The pilot bearing did not fit in the flywheel correctly. It chatters bad when I take off with a load. If you have time to wait for shipping, I'd go to Rockauto and probably get the LUK set.
I might have this backwards, but I think the DMF uses the 12" clutch and the SMF is 11", don't worry about the size so much as single or dual mass.