E4OD to ZF5 writeup
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Senior User
Joined: Jan 2007
Posts: 242
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From: Norheimsund, Norway
E4OD to ZF5 writeup
Many years ago I did this conversion. I remember it was a great write up here with alot of photos. It helped me getting started. The truck is sold. And I am over in the 73-79 older classique forum owning a 1977 F150. But I know of another one in the Norwegian F-serie Club who wants to do the conversion. Cant find that write up. Anyone who can help me out on this one?
Cargo Master
Joined: Oct 2005
Posts: 2,298
Likes: 27
From: NJ
I've done this swap on several trucks, small block big block and diesel... I'm sure there are documented swaps if you google it, but it really is about as simple as you can get. ZF5 just bolts in place.
Small block and IDI you'll have to move the trans crossmember back a bit Small block ZF5 is significantly longer than C6 or NP435 and requires different driveshafts and all new holes drilled in the frame for crossmember. IDI I just bolted the front hole of crossmember in place of the back hole in the frame then marked and drilled new holes for the ones that didn't match up. I slightly elongated the holes in the crossmember for the trans mount, then it all fit nicely. Since I was using a C6 crossmember I used the short C6 mount to maintain reasonable driveshaft angles.
Aside from that it's all a bolt in deal. Try to get a ZF5 floor pan that bolts on for the shifter. You'll have to cut that for the NP208 shifter location, or you can modify your C6 tunnel cover for the ZF but be aware the later ZF5 tunnel covers are taller so without a taller cover it won't be as clean an install and factory shift boots may not install nice, don't know I always had the tall covers to use.
Small block and IDI you'll have to move the trans crossmember back a bit Small block ZF5 is significantly longer than C6 or NP435 and requires different driveshafts and all new holes drilled in the frame for crossmember. IDI I just bolted the front hole of crossmember in place of the back hole in the frame then marked and drilled new holes for the ones that didn't match up. I slightly elongated the holes in the crossmember for the trans mount, then it all fit nicely. Since I was using a C6 crossmember I used the short C6 mount to maintain reasonable driveshaft angles.
Aside from that it's all a bolt in deal. Try to get a ZF5 floor pan that bolts on for the shifter. You'll have to cut that for the NP208 shifter location, or you can modify your C6 tunnel cover for the ZF but be aware the later ZF5 tunnel covers are taller so without a taller cover it won't be as clean an install and factory shift boots may not install nice, don't know I always had the tall covers to use.
Tuned
Joined: Feb 2005
Posts: 478
Likes: 10
From: Minnesota
I've done this swap on several trucks, small block big block and diesel... I'm sure there are documented swaps if you google it, but it really is about as simple as you can get. ZF5 just bolts in place.
Small block and IDI you'll have to move the trans crossmember back a bit Small block ZF5 is significantly longer than C6 or NP435 and requires different driveshafts and all new holes drilled in the frame for crossmember. IDI I just bolted the front hole of crossmember in place of the back hole in the frame then marked and drilled new holes for the ones that didn't match up. I slightly elongated the holes in the crossmember for the trans mount, then it all fit nicely. Since I was using a C6 crossmember I used the short C6 mount to maintain reasonable driveshaft angles.
Aside from that it's all a bolt in deal. Try to get a ZF5 floor pan that bolts on for the shifter. You'll have to cut that for the NP208 shifter location, or you can modify your C6 tunnel cover for the ZF but be aware the later ZF5 tunnel covers are taller so without a taller cover it won't be as clean an install and factory shift boots may not install nice, don't know I always had the tall covers to use.
Small block and IDI you'll have to move the trans crossmember back a bit Small block ZF5 is significantly longer than C6 or NP435 and requires different driveshafts and all new holes drilled in the frame for crossmember. IDI I just bolted the front hole of crossmember in place of the back hole in the frame then marked and drilled new holes for the ones that didn't match up. I slightly elongated the holes in the crossmember for the trans mount, then it all fit nicely. Since I was using a C6 crossmember I used the short C6 mount to maintain reasonable driveshaft angles.
Aside from that it's all a bolt in deal. Try to get a ZF5 floor pan that bolts on for the shifter. You'll have to cut that for the NP208 shifter location, or you can modify your C6 tunnel cover for the ZF but be aware the later ZF5 tunnel covers are taller so without a taller cover it won't be as clean an install and factory shift boots may not install nice, don't know I always had the tall covers to use.
Cargo Master
Joined: Oct 2005
Posts: 2,298
Likes: 27
From: NJ
Use a Luk 07-225 flywheel and clutch set. RockAuto was cheapest by over $100 when I got mine but has gone up some.
Clutch pedal and master just bolt in. The firewall is marked for master location, on one of my '86 trucks I needed to cut it out and on the other it was already cut with a blockoff plate bolted in place. You will need to install a firewall brace plate or the firewall will crack and your clutch won't work. ford firewall page This bolts in place with at worst some minor hammering or grinding. I did not install the top bolts as the top of the brace was not a tight fit to the cab and I figured it avoids potential leaks as well.
Clutch pedal and master just bolt in. The firewall is marked for master location, on one of my '86 trucks I needed to cut it out and on the other it was already cut with a blockoff plate bolted in place. You will need to install a firewall brace plate or the firewall will crack and your clutch won't work. ford firewall page This bolts in place with at worst some minor hammering or grinding. I did not install the top bolts as the top of the brace was not a tight fit to the cab and I figured it avoids potential leaks as well.
Cargo Master
Joined: Oct 2005
Posts: 2,298
Likes: 27
From: NJ
I will say my trans length comments are comapring every factory trans combo except E4OD or AOD. I cant' comment on those. If you need measurements from a Super Cab or Crew Cab I can let you know driveshaft lengths and crossmember positions. I can also measure bellhousing to trans mount and rear flange for transfer case. Both my trucks have NP208 cases, but a fixed yoke 1356 is approximately the same dimensions. If you have one of those goofy slipyoke transfer cases I can't help with that, I've always avoided them. I can say a NP205 is appreciably different in dimensions and will not work without driveshaft and crossmember modifications. It also puts the front shaft right where the drivers exhaust would be, a problem on a gas truck but unlikely to be an issue with a diesel. Also, for a 205 at minimum a torque brace to the frame is required and a full crossmember would be prudent, so as not to break the aluminum ZF5 case.
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