1986 F250 2wd 3 speed Auto to ZF5 swap - Ford Truck Enthusiasts Forums

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1986 F250 2wd 3 speed Auto to ZF5 swap

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Old 08-12-2018, 11:21 PM
86 6.9
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1986 F250 2wd 3 speed Auto to ZF5 swap

I bought a 2wd ZF5 out of a 1992 F250 extended cab with a 7.3. I got the transmission and the cross member out of the 1992. I took it apart put a speedometer drive gear in it and bored out the hole in the back of the case for the speedometer cable. I got a drive shaft out of a 1990 regular cab 2wd with a 7.3. I bought a complete clutch kit, flywheel and everything for a 1990 F250 7.3. I have a 1985 F150 parts truck that I took the pedal assembly from bolted those in, no problem. I made a template for the clutch master cylinder from the 1985, havenít put that all together yet, but it seems like it will go no problem. The clutch and transmission are bolted up and then I put the cross member in, thatís when the first problem comes up. My question is what cross member do I need to use? The one from the 1992 doesnít line up with the pre-existing holes in the frame. The one for the auto trans wonít line up either or the one from the 1985 parts truck(it was a 302 with a 4 speed. Any help would be greatly appreciated. Iím doing all this to a 1986 F250 with a 6.9 diesel.
 

Last edited by 86 6.9; 08-12-2018 at 11:23 PM. Reason: Info
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Old 08-13-2018, 03:28 AM
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Originally Posted by 86 6.9 View Post
My question is what cross member do I need to use? The one from the 1992 doesnít line up with the pre-existing holes in the frame. The one for the auto trans wonít line up either or the one from the 1985 parts truck(it was a 302 with a 4 speed. Any help would be greatly appreciated.
I would use the 1992 crossmember that came with the trans. I just went through this with an M5OD 5spd swap in my 1984 F150 (gas). I had purchased a crossmember that was correct for the 5spd transmission, but it had come out of a 1994-1996 F150, and like you, the crossmember didn't quite line up with the holes in my 1984 frame. I slid the crossmember rearward so that the trans mount studs were centered in the mounting slots, and then measured where the holes needed to be in the frame (approx 1.25" further back). Drilled two new holes, then reinstalled the crossmember and bolted it down. For the gusset brackets that go from the crossmember to the top of the frame, I modified them slightly with an extension piece so that I could utilize the mounting bolts that were already in my frame (Those bolts couldn't be removed on my truck without lifting the cab, so I figured it would be easier to modify the brackets).


 
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Old 08-14-2018, 05:42 PM
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I did the exact same swap on my 89 diesel, except I had a donor 89 zf truck, so I had it a little easier. Did all the swapping you did. The lower crossmember for the c6 and the zf were exactly the same on my truck. But my truck already had a set of holes rearward drilled in the lower part of the frame c-channel, and when I used those holes, the lower crossmember for the c6 bolted right up.

The short upper crossmembers for the c6 would not bolt up. The short upper zf crossmembers from the other truck did bolt right in. The zf short crossmembers had more of a offset to them, since the lower crossmember had moved back about a 1 inch.

I had a plan, if I had to use the short upper c6 crossmembers, I was going to bolt them on the lower crossmember in it's new location, and then see which one of the two upper frame holes could be used, and mark the c6 upper crossmembers through the existing upper frame hole. Then drill a custom hole in the c6 crossmember and at least use one bolt to bolt them in at the top. Looking at it, I figure it would have been almost impossible to drill two new holes in the upper part of the frame with the cab in place.

Since I had a 89 donor, I found there is a plug under the brake booster where the transmission/transfer case harness plugged in. I unplugged my c6 harness, and plugged in the zf harness, and it all worked, no wiring to do at all. Not sure if you can get away with that on your truck, but I will warn you the manual trans harness has a jumper made in it right at the plug, to jump the two red/blue wires. These are the wires that go to the neutral safety on your c6. If you do not jump these wires after taking the c6 out, it will not crank over.
 
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Old 08-15-2018, 08:35 PM
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Thanks for yalls assistance. I figured out what I need I just have to find a truck to get one from. What I have found is a cross member from a ZF truck regular cab 2wd, Iím 99%sure will bolt right up to what I have. I found one in a salvage yard truck in a 1989 but the guy is keeping the truck together and wonít come off of the parts. It has a very much more pronounced ďbendĒ in it where the transmission mounts goes. It looks (I took some measurements as well) like it will keep the holes on the bottom of the frame lined up in the original location. Iíll update as soon as I find one. I have a Banks turbo kit I picked up from a junkyard for $200, hopefully that all goes in decently well after I get all this buttoned up.
 
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Old 08-16-2018, 03:21 AM
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Originally Posted by 86 6.9 View Post
Thanks for yalls assistance. I figured out what I need I just have to find a truck to get one from. What I have found is a cross member from a ZF truck regular cab 2wd, Iím 99%sure will bolt right up to what I have.
I did the very same thing. I found a 5spd crossmember from a newer truck (95+ I believe) and it had a very pronounced curve in it, and I was sure it was going to work. I still had to re-drill the holes. It was very close, but not quite close enough. I'm sure there's a better chance of an earlier crossmember fitting better (like an 88-91), but do let us know what you find out. I'm curious now. I was trying like hell to use factory parts that all bolted back in place, but it just didn't work for me. I only had to drill one hole in each side, so that wasn't so bad.



 
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Old 08-17-2018, 09:59 AM
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I found a cross member out of a 1989 F250 5 speed regular cab. I had to elongate the slotted hole on the cross member where the lower part of the upper brackets go on the crossmember. I had already ďwolleredĒ out the hole in the frame where crossmember bolts in with the single bolt, trying to get the crossmember from the extended cab truck to fit, so Iím not sure if it would have been correct but it looks like it would have been. I painted it yesterday after I did my modifications, so this evening Iíll bolt it all up and be done with that part.
 
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