I have a 96 f250 powerstroke with a bad trans (E4OD). I want to swap a zf5 into it. Would my old transfer case bolt up? The guy is selling everything to do it on craigslist for 600. I was wondering if anyone on here has done it and what the biggest challenges were. Thanks

 

If the tranny you are looking at is from a diesel 4X4, or a OBS superduty(F450) your transfer case will bolt up.If the donor truck is a 4X2, then it will not have the correct tail housing. The gasser trannys have a different bolt pattern on the bell housing, and will not fit the PSD. This is a fairly common swap., and there are several write ups in this forum. The search button is your friend here.

 

yep - pretty easy swap once you have everything together and Tom's got you all squared on what goes with what. definitely search on 'zf5 swap' though - prob a dozen threads on it.

make sure he's actually selling everything though, otherwise you'll be shopping for months for the other stuff like i was:
4x4 tranny, shifter, boots, zf5 4x4 crossmember, driveshafts, pedal box, clutch hydraulics... those are the essentials if i recall correctly

a manual PCM is nice to have, but you can have yours reflashed or use a chip to cure the romp.

 

I just completed my e4od to zf5 swap last week if you have any questions along the way I'll be glad to help