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ZF S5-42 Swap confusion

 
  #1  
Old 01-09-2016, 05:22 PM
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ZF S5-42 Swap confusion

I need some help with the swap I plan on doing in the near future.
My truck is a 92 f150 4x4 302 t18 four speed with the 1356 tcase, reg cab short bed.
Clutch is the external slave with everything from the clutch to the pedals being brand new minus the hydraulic line.

Been reading into the zf s5-42 swap, and so much info and swaps for different motor etc has me scratching my head.

In order to do this swap, what will I need to do in order to make it work?

At the moment I'm in the research phase so no parts collected.

I would appreciate all the help I can get.
 
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Old 01-09-2016, 06:25 PM
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You need to tell us what motor you have.
 
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Old 01-09-2016, 06:54 PM
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Originally Posted by jas88 View Post
You need to tell us what motor you have.
I knew I was leaving something out. lol
I edited the org post.
 
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Old 01-09-2016, 07:11 PM
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There's 3 types of zf5s. ...diesel, small block (302, 351, 300) and big block. You need a small block zf and the associated hydraulics which will include an internal slave.
 
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Old 01-09-2016, 07:34 PM
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I know about the internal slave and that a new line needs to be installed.

I'll just post the questions I have about the swap.


Will the stock clutch and starter work with the s5-42?
What yrs do I need to be on the lookout for? I ask because I have the electronic speedo.
Will my stock drive shafts need to be modified? 4wd.
Will the cross member need to be moved? and can I use my t18 cross member?

I would of thought that there isn't much difference in length between the t18 and zf5, but not sure on that either.
 
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Old 01-09-2016, 07:46 PM
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1) clutch and starter will work

2) any year zf will work

3) you'll need shaft work

4) you can make your x member work, or source a stocker if what you have is something funky
 
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Old 01-09-2016, 07:55 PM
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Alright.
What will need to be done to both driveshafts?
 
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Old 01-09-2016, 08:01 PM
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Lengthen front, shorten rear.
 
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Old 01-09-2016, 10:46 PM
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Damn, I just had my rear balanced and new joints and yoke put on.
 
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Old 01-10-2016, 07:50 AM
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Get the rear shaft shortened. You'll reuse all of your new joints (but still need to have it rebalanced obviously)
 
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Old 01-10-2016, 08:01 AM
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I know this doesn't apply to the original post, but if going from an an MD05 or whatever that is to the zf5 small blocks, do the same things apply regarding the length of the trans ? Or do these have same lengths, front and rear splines ?
 
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Old 01-10-2016, 10:20 AM
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From what I've read, all of the aluminum or magnesium transfer cases Ford has ever used will interchange between whatever transmissions they came with. So the output of all F-series 4WD transmissions must be the same, which would apply to the Mazda 5 speed and the ZF 5 speed.

I'm not sure about the 2WD transmissions. There are definitely some differences (some will have slip yokes, others fixed yokes). And there may be others (different output shaft sizes?). I don't know if a 2WD ZF would work with the driveshaft off a 2WD Mazda.

I also don't know about input shafts. I could imagine there could be differences there, but a new clutch would take care of that.

And I'm not sure, but I'd be surprized if the Mazda and ZF transmissions are the same length. Generally speaking, if you change transmissions you will need to change your driveshafts. But that's not that big a deal. Everyone gets so worked up about what truck they need to find in a junkyard to get the right driveshafts. I had both driveshafts shortened in my Bronco a couple years ago, $250 for the pair. Lengthening might be SLIGHTLY more, but changing length on a driveshaft isn't that expensive.
 
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Old 01-10-2016, 10:27 AM
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In order to do this swap, looks like I'll have to find a donor truck.
I was thinking I just needed the trans and cross member.

I think when I had my rear driveshaft repaired, they charged me a little under $150.

Did ford ever put these zf's in a reg cab short bed f250-350?
 
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Old 01-10-2016, 01:34 PM
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Originally Posted by PRIMERED79 SHORT BED View Post
....Did ford ever put these zf's in a reg cab short bed f250-350?
I'm almost positive that Ford never made regular cab short bed F-250s or 350s at all. Only heavier short beds are F-250 Super and Crew Cabs
 
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Old 01-10-2016, 02:23 PM
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Lengthening driveshafts costs substantially more than shortening, as shortening is simple and reuses what's there. Lengthening, at least by a shop, will entail building essentially a new driveshaft. They'll cut an entirely new tube to the new size and weld on your ends (whatever they may be). It's possible to sleeve a driveshaft but virtually any reputable shop won't do that for you...it's a safety issue. You could sleeve your own however, and the front doesn't need to be balanced unless you drive fast in 4x4 or keep your hubs locked in 2wd during the winter.

You can also build your own and get it balanced, or leave it unbalanced like I said above if you don't go fast in 4x.
 

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