ZF 5 Swap
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From: Penns Woods
ZF 5 Swap
I am very close to purchasing a used ZF for $600 for my 84 150. I have the truck stripped down to the frame so this is the time to install a ZF. I could not find a definate ansewer on what will need to be modified. I heard the cross member needs modified and that I will need a shorter driveshaft because the zf is longer than most. Will a NP208 transfer case bolt up? Stock flywheel? All of these ansewers came from a classic bronco site...so I don't know if they apply to me. Thanks in advance!
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You don't say what motor and transmission was in the vehicle. Your flywheel will have to match your engine; e.g. a 4.9L uses a flywheel with 0 oz balance, a 5.0 uses 50 oz imbalance and a 351W uses 28 oz imbalance. I'm not familiar with the NP 208 but Ford uses a standard 6 bolt flange on the transmission tailshaft housing and transfer case. If the NP208 has that pattern, it should bolt up.
As for the driveshafts, you will need to measure the overall length of your existing transmission from bellhousing/engine mounting surface to the rear face of the tailshaft housing. The 4X4 ZF I bought is 29-3/16" overall length. By adding or subtracting the difference in overall lengths of the two trannys you can figure how much difference there will be in driveshaft length. The ZF was 2-9/16" shorter than my E4OD so the rear driveshaft needed to be 2-9/16" longer while the front needed to be that much shorter.
As for the cross member, the Mazda M5R2 x-member (readily available in junkyards) is virtually a direct bolt in with the ZF swap into the '87-96 trucks. I don't believe the frame was changed between the 80-86 and 87-96 so it may work there also. I also have the '96 ZF S5-47 in my truck and the only real mod to the Mazda crossmember was widening the trans mount bolt holes to fit the '96 mount. I obtained many of the parts from an '88 F-150 manual trans truck.
As for the driveshafts, you will need to measure the overall length of your existing transmission from bellhousing/engine mounting surface to the rear face of the tailshaft housing. The 4X4 ZF I bought is 29-3/16" overall length. By adding or subtracting the difference in overall lengths of the two trannys you can figure how much difference there will be in driveshaft length. The ZF was 2-9/16" shorter than my E4OD so the rear driveshaft needed to be 2-9/16" longer while the front needed to be that much shorter.
As for the cross member, the Mazda M5R2 x-member (readily available in junkyards) is virtually a direct bolt in with the ZF swap into the '87-96 trucks. I don't believe the frame was changed between the 80-86 and 87-96 so it may work there also. I also have the '96 ZF S5-47 in my truck and the only real mod to the Mazda crossmember was widening the trans mount bolt holes to fit the '96 mount. I obtained many of the parts from an '88 F-150 manual trans truck.
Originally Posted by gustang818
Last month I put a ZF in my '92 F-150 4X4 302 that previously had an E4OD trans. I put a new motor in with the existing E4OD and before I finished the engine swap, came across a ZF S547 for a good price.
Driveshafts
The ZF trans is 29-3/16" long and the E4OD is 31-3/4"; a difference of 2-9/16". Therefore you want your front d/s 2-9/16" shorter and the rear 2-9/16" longer.
The front driveshaft from the '88 worked but the rear was damaged and I think the wheelbase was a little shorter. After looking for about 2 weeks I had a local driveshaft shop re-tube my rear drive shaft 2-9/16" longer and balance it. It was about $100.
Transmission cross member
I also got the cross member out of the '88 F-150. Once again, find a donor with the Mazda manual trans. The E4OD cross member is entirely different and won't work without extensive mods. The tranny mount bolt holes in the x-member were narrower than the ZF mount. A little work with the cutting torch widened the holes. The new cross member mounts in bolt holes that exist in the frame from the factory. I think there are 2 bolt holes in the Mazda x-member that don't exist in the E4OD so save your fasteners. Be sure to get the whole x-member including the braces.
Driveshafts
The ZF trans is 29-3/16" long and the E4OD is 31-3/4"; a difference of 2-9/16". Therefore you want your front d/s 2-9/16" shorter and the rear 2-9/16" longer.
The front driveshaft from the '88 worked but the rear was damaged and I think the wheelbase was a little shorter. After looking for about 2 weeks I had a local driveshaft shop re-tube my rear drive shaft 2-9/16" longer and balance it. It was about $100.
Transmission cross member
I also got the cross member out of the '88 F-150. Once again, find a donor with the Mazda manual trans. The E4OD cross member is entirely different and won't work without extensive mods. The tranny mount bolt holes in the x-member were narrower than the ZF mount. A little work with the cutting torch widened the holes. The new cross member mounts in bolt holes that exist in the frame from the factory. I think there are 2 bolt holes in the Mazda x-member that don't exist in the E4OD so save your fasteners. Be sure to get the whole x-member including the braces.
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masterguns2003
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Jan 24, 2008 04:36 AM
