Truck in question is an 89 F250 4x4 with the 7.3 NA IDI.

Currently its got a ZF transmission with a manufacture year of 1993. Apparently by this time ford was using an electronic sensor for the spedometer, since my truck has the cable speedo, its just dangling under the truck, zip tied to a frame rail so it doesn't drag/get destroyed.

Additionally the ZF in the truck has a major break in the bellhousing. In short, it will need to be replaced soon.

This leads to my question, what are my options for replacing the transmission? I'm pretty sure I can source a reman zf with the proper speedo for somewhere in the range of 1200-1400 plus core. That being said, I've read that the ZF is a somewhat noisy transmission when working properly. Depending on pricing I'd be interested in an aftermarket solution. Allison and Tremec come to mind but I've had some trouble finding if they make a model compatible with the IDI and thats not even considering the older style speedo cable and/or if I'd have to replace the transfer case with something else to be compatible with an aftermarket transmission (adding significantly to the cost).

So what thoughts occur to you all as potential replacements without breaking the bank? It would certainly be nice to have a functioning speedometer and a transmission that I wasn't a little worried might shear off completely at some point.

Thanks!

 

Being 4x4, the speedo cable should be driven by the T-case rather than the trans. What T-case is in it?

 

Now that you mention it, you're absolutely correct. The speedo hookup is in the t-case. Not the trans.

Does it show this is my first 4x4 truck? heh. I'll have to go back and find the plate or stampings on the t-case tonight.

 

A properly installed and properly built ZF5 is not noisy ... The noise comes from improper building and installation as well as towing age.

I personally would get a rebuilt built by someone that knows the intricacies of the ZF5, they are difficult to rebuild properly, precisely and require special tools!
$1400 sounds cheap!

Do it right and use a DMF (Dual Mass) flywheel ... Use a SMF (Single Mass) and it will grow a noise that most cover up by filling the transmission with a gallon of oil from the top over filling the transmission.

To most the noise of an SMF doesn't bother them ... I run an SMF filled from the top, I pull heavy a lot.

Adapting some other transmission is not worth the pain!

-Enjoy
fh : )_~

 

We have ZF-S5-42s and SMFs in both our '95 4x4 PSDs, filled only to the bottom of the fill plug. We hear the gear rollover when we're in first gear, creeping down the ridge toward our cabin, at idle and clutch fully engaged. I can't say that I recall hearing it at any other time. I would not describe our ZFs as "loud" by any means.

 

Honestly, if the transmission works just fine... pull it and have a local welding shop weld up the bellhousing.
I'm sure it would be cheaper than any other solution, even if they need to add a support plate somewhere.
I've seen it done a couple of times, and apparently it works just fine.

Honestly, the ZF S5-42 transmission is a pretty good one - it's pretty rare to hear about major issues with them.
Usually, it's just the synchros which are going(after 25+ years of service), but other than that, they just work.

With a SMF, you usually have to overfill the transmission 1 quart to quiet it down, but it works just fine.

 

even if they used the 93 transfer case, it should still be a borg warner 1356 t-case.

 

I'll have to look into getting it welded up. I had it stuck in my head that the VSS was in the trans not the xfer case. Silly me.

I'm pretty sure that is the case, it seems that maybe the back case housing is different. Mine has an electronic VSS on top of the tail, as opposed to a hole for the cable VSS in the side of the tail. I wonder if its an option to switch out the tail housing or if thats a good way to screw up the entire transfer case.

 

in 92 ford went to the VSS in the tail shaft. by 93 all the older cable driven speedo cases were long gone and only VSS cases were used. to put a cable tail shaft on, you would also need the gable drive on the output shaft.

it would be easier and probably cheaper to find a cable speedo t-case.
the cable speedo BW1356 t-case was used from 86 to 91 in just about all F250 and 350 pickups, plus some 150 pickups. so there are many out there, and the t-case is not diesel specific. one from a 300 six truck will work just as good as one from a diesel or 460 powered truck.
the case currently in my 88 came out of a 302 powered 90 bronco.

 

That is some awesome info, thank you so very much.

 

Didn't they move to the rear end?

-Enjoy
fh : )_~

 

not sure when that was done. they might have moved to the rear for VSS and left cruise control VSS in the transfer case.
i know my early production 92 had the VSS and cable drive in the t-case with the cable drive blocked off, the 93 and later trucks we worked on just had a sensor in the tail shaft.
i never really paid attention to what that sensor was for, because i never had to mess with one other than remove it to send the trans out for rebuilding.

 

I don't know all the combos ... I'm hoping to learn something here.

See I thought it happened earlier then 92 ...
My 91 ZF5 does not have a VSS port, it had factory cruise control.
My 94 ZF5 does not have a VSS port, it has factory cruise control.

The location is cast, but not machined.

Just trying to learn ... Not argue!

-Enjoy
fh : )_~

 

When I said the VSS was on top of the transfer case, I was assuming thats what it was. I could be totally wrong.

 

i realize that.
i should be more specific. on the 88 to 91 trucks the sensor was part of the speedometer cable end that goes into the tail shaft.
on the 93 trucks there was no speedometer cable, just the sensor.
now on my 88 F-350 there was no sensor or tone ring in the rear. even though everyone and their brother swears the ABS sensor and tone ring in in the rear.

i even had a dealer service "tech" tell me it was there, and was stumped when i told him to find it and he could not.
the only thing i can figure was that that truck was an early production 88, built in Sept of 87.
the 88 F-SuperDuty has 86 F-350 axles in it so it has no axle sensor or tone rings either.

Ford did a lot of funny things back in the old days.
i had a 69 Mustang Grande coupe with a 351C, C-6 trans, and 4 wheel disc brakes. it was a corporate order car "that was never made", custom made for a ford executive.
there was also the 79 Fairmont Futura with the 351W engine and 4 speed trans with 4 wheel disc drakes.
another corporate order car that "was never made"