I bought a 1990 zf 5spd with 1356 bw transfer.I'm puting this in a 79 F150 4x4 thats got a 460 with a 4spd. and a 205 transfer.My question is will the 205 bolt up to the zf?Also what clutch do I buy?At present I'm running a redrilled internal balance 390 flywheel with 84 12" clutch?

 

Nope, the 205 is not a direct bolt-on to the ZF.
The clutch you want is the one for the ZF. If you don't have the correct flywheel (and you don't) you need to either redrill your 390 flywheel or purchase the correct one.

 

fredic,is there a clutch & flywheel to be bought?if so where?what does one need to do to mate the 205 up to the zf?I've seen trucks on ebay listed this way.last one was a 79 f 250 4wd with a 7.3 zf 5sp in kansas, he was question about the setup, he said that what was done,a with a zf with a 205.thanks

 

Why do you want to ditch the BW1356 for the 205? The 1356 has a much lower low range, is lighter weight, and is pleanty strong for most any application. Just protect it from impact with rocks and trail obsticles and you shouldn't have a bit of trouble out of it. I would take a 1356 over a 205 any day, but thats just me.

 

The np205 will bolt in, but you have to notch the ZF's mounting flange for the upper shift rail. Just lay the np205's mounting flange gasket on there as a guide, mark the notch and remove the material. Best bet would be to drill the round part of the nothc through, then use a hack saw or saber saw to finish the notch.

If you use the BW1356, you'll need the front drive shaft lengthened, and the rear shortened. The BW1356 is about 6" londer than your np205 setup. And double check its width, you might not be able to fit it up between the frame rails anyways (don't quote me though).

 

I replaced my B&W T-19 with a ZF 5 speed on my 87 460. I don't know what 4 speed you have. The zf's input shaft was much larger in diameter that the T-19, so a different clutch was necessary. I didn't have any trouble getting the right clutch, I just ordered one for the year truck that the ZF came out of from Autozone. The flywheel was another story. The new clutch was much bigger than the stock unit and the stock flywheel was only drilled for the stock clutch. I ordered a new flywheel using the same information I used to order the clutch, also from Autozone. When I went to pick them up, the flywheel did not have the correct bolt pattern for the clutch. Of course, the guy at Autozone was stumped at that point because "that's the part number in the computer". I called the manufacturer of the flywheel and got the same response. I was about to give up and find a machine shop to redrill my stock flywheel, but just for ****s and giggles, I ordered one from Advanced Auto Parts. The one they got had 3 different patterns, one of which matched the clutch! Advice: Measure the input shaft diameter and count the splines before you go to pick up your clutch. Make sure its right before you leave the store. Pull the clutch out of the box and lay it on the flywheel and make sure it matches before you leave the store. I found out all this after getting home. Major waste of time. A couple of other notes: The clutch for my 4 speed had 6 bolts, the clutch for the ZF had 8. The autoparts stores I called couldn't get the pressure plate bolts. I had to go to Ford. They were cheap, but the closest dealer that had them in stock was about an hour ride. My 87 had a hydraulic clutch on the T-19. The slave cylinder fit the ZF perfectly. I imagine your clutch is mechanical, so you may have an issue there. Finally, the only other problem I had was due to the bell housing being part of the transmission case. When I tried to slide the input shaft into the clutch, the top of the bell housing hung up on the seam between the fire wall and the cab floor. To get past this, I just jacked up the front of the engine an inch or two. Your 79 body may be different, but I wouldn't be surprized if they're similar.

 

Excellent point turbo! The seam that runs around the cab/tranny hump will most likely need to be trimmed. A couple people in the 73-79 forum have notched the seam, and just hammered it flat against the firewall. Then there is the hydraulic clutch issue mentioned by Turbo as well. It shouldn't be too hard to retro fit one in there, just remeber to reinforce the hole with a peice of 1/8" plate steel that will probablt extend 1.5" around the outer edges of the Master cylinder. The stock 70's cab wasn't designed to have that kind of pressure exterted on it, and it will flex resulting in poor clutch movement.