E40D swap to ZF S542
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From: Chico USA
E40D swap to ZF S542
I have a 90 Bronco with a 351W and an E40D. The E40D is slipping in 2nd and 3rd. I want to swap out the E40D to a ZF S542. It bolts up but I am told that they use different transfercases. Does anyone know which t-case the zf s542 uses? The E40D is routed through a BW1356. Also how reliable is the ZF? Does it have any downsides? I am also wondering if I will need a manual computer to run a manual? I assume that it will need a new driveshaft also. I may just reluctantly rebuild the E40D because of the price of the swap but I want that 4.14 first gear(I think that's correct), the overdrive and the reliability in the ZF. Any information regarding either transmission and the swap is much appreciated. Thanks.
Alex
Alex
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Joined: Nov 2002
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From: Horicon US
E40D swap to ZF S542
a new zf will cost more than it would to fix the e4od. the e4od is the strongest auto for a ford. but if you want to go with the zf you have to lose about 8 inches from your front drive shaft and extend your rear 8 inches due to the fact that the zf is about 8 inches shorter, and a lot of extra expenses. if i were you i would take your e4od to get fixed befor it totaly goes, i recked mine, i lost every thing but park. i had basicly every thing in it replaced and some things upgraded and a 3 year warrinty for 2,400$.
Posting Guru
Joined: Aug 2001
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E40D swap to ZF S542
I think the ZF 5-speed has a 5.72:1 first gear."Ford has no current plans to offer a five-speed manual with the fuelie 351 unless there's sufficient consumer demand", according to a roadtest article of a EFI351-powered Eddie Bauer Bronco in 4-Wheel&Off-Road's 3/88 issue.The swap could be done,but you'll probably need computer mods,plus a fresh ZF tranny.The ZF 5-speed was used behind 351-powered pickups,so it's not an impossible swap,but it might be cheaper/easier to build up your current E4OD.The 351/ZF 5-speed would be a super-nice combination in a Bronco,however.Good luck,whatever you decide to do.
Post Fiend
Joined: Nov 2002
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From: Memphis, TN
E40D swap to ZF S542
The computer won't necessarily miss the E4OD - I helped a friend swap to an M5OD in his '93 Bronco and his CEL hasn't come on yet! Check his writeup on his site:
http://www.broncodata.com/
http://www.broncodata.com/
Senior User
Joined: Dec 2000
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E40D swap to ZF S542
It was suggested to me today, that one way to do the auto to manual swap is to get a solinoid (sp) pack and plug the E4OD conector into that. Wrap it in plastic and mount it in weather proof box to make the computer happy. Elliott
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