The ZF5 always comes up as a trans of choice, along with the lighter duty Mazda 5 speed, as a means to get overdrive on our trucks.

I've been collecting parts for that 2 wheel drive swap for some time, and wanted to throw out some info for those who may be considering it. All total, to convert from auto to this manual trans, you're looking at close to $2,000, if doing all but the rebuild yourself!!

That means buying the trans, new clutch, pedal cluster, slave and master cylinder, trans rebuild fee, seals, gaskets, bearings, synchros, tunnel cover, drive shaft redo, new starter, flywheel resurface, oh, and new/used flywheel, and fabrication work on firewall.

Other issues to beware: 1). It is difficult to find non Chinese bearings/parts. The only place that has them is General Truck Parts, in Chicago. "They only get parts straight from the ZF factory in Germany." 2). Price. Ouch. $250 for the syncros alone!

People have (on the forum) recommended other suppliers for the bearings, but when I called, those suppliers could not guaranty the bearings were not stamped 'made in China.' Beware repackaging. Chinese bearings, I've read, last about 1 year. Don't just take someone's word for parts quality. Call the place they recommend and ask where the parts are made, or risk doing your rebuild twice!!

It is not an inexpensive swap. Of course I could live dangerously, as another forum member did, and install the trans w/o a bench rebuild. His lasted two weeks before he had to drop it and rebuild it. My trans was in a landscaping truck, so, I believe, a freshening up is on the horizon. Good luck.

 

... and that's why, in my opinion, a new Tremec TKO is a better buy... It was pretty much bolt-on behind my 70's FE.

 

HIO--what specifically are you referring to?

From what I have seen the Tremec costs significantly more than my ZF project, which, btw, is only so expensive b/c I'm converting from auto to manual.

Isn't the Tremec a passenger car trans? beefed up? Time will tell on that, especially if hauling/towing.

 

I'm referring to parts availability plus the trans rebuild issue because most everything from the salvage yard will need a rebuild sooner than later. The cost difference is time gathering everything plus about $800 to $1000 which equates to "certainty" since the Tremec I got is new... A TKO-500 is rated at 500 ft.lbs. of TQ. The TKO-600 at 600 ft.lbs.

My costs:
Trans with short input shaft: $2300
Clutch kit: $400
Shift arm, shift ball, boot, reverse pigtail, trans mount: $200
Coupling shaft from a C-6 equipped truck: $100

 

Anyone considering an OD manual trans swap for fuel savings needs to put the pen to the paper before they start.

 

I am still searching for the quality ZF 5 kit that does not contain bearings made in China. And, I want it at a good price! This is difficult. Some companies get angry when you ask where the parts are made! Never assume; Always call and ask.

After a lot of research, I find that if a site or company does not tell you up front on their site where the parts are made, they are most likely 'made in China.'

Examples of this: Raybestos, Summit Racing with their new Summit Carbs, DUI distributors, Ebay sellers, and more.

I think co's try to hide or delete the country of origin so they can maintain a facade of quality, and keep profits up even higher. Ouch. I interpret that as a betrayal.

Even SKF, a Swedish bearing giant, sold on Rock Auto, when you search around, you find that they too are manufacturing in China. So, you get a nice box, and on the bearing is stamped China.

Forget Ebay. Even the sellers listing Koyo bearings, which are good Japanese bearings, are questionable. Read the poor reviews of customers who bought the kit to find again, great boxes saying Koyo, with bearings stamped China.

THE ONLY PLACE TO BUY QUALITY ZF KITS IS GENERAL TRUCK PARTS IN CHICAGO. But you pay for it. The synchros alone cost the price of a full Chinese kit.

Good luck.

 

My opinion is that it's worth while to do the swap before throwing money towards a rebuild as long as it is for sure coming from a running truck. Or at least a truck with another known issue besides the trans. After the swap, all the hard work is done and the tranny can be dropped in a mere couple to 3 hours if not less. And if it only lasts 2 weeks, that's 2 full weeks of assurance that after you get it rebuilt, that it will bolt right back up with no issues?
We're talking firewall reinforcement, cross member fabrication, trans tunnel alterations, hydraulic clutch configuring and driveshaft altering (probably forgetting other things). If just a 2wd, a driveshaft alteration alone will set you back +/- $150. And you're looking at a weeks worth or more of just getting the trans to fit.

I did mine only to find out that the rear seal is leaking. At least the tranny ain't got to come back out but at least I know it works before throwing money at a complete rebuild.

Plus it's always easier the second time. LOL

 

Yes, you make some good points. Thanks.

I guess my trans is a mystery. I bought it from a guy in another part of the state who dropped it off for me. All he told me was that it came out of a landscaping F250. Although a bench inspection can ck gears and synchros, it really can't tell you about the bearings.

I was simply trying to cover my bases.