I thinking of converting my 1977 f100 302 from a c6 to a ZF5. It's 2 wheel drive and will stay 2 wheel drive. I have all the needed pedals. The ZF5 came from a 302 so it should mount up to the motor. I know that ZF5 will need a hydraulic clutch, new drive shaft. Any insight will be appreciated.

 

You will want one from an 87 to 91 as they have a speedo drive, anything newer will not.

 

Yep, you need to install a hydraulic master - you need to do some custom work here, there is nothing factory that fits. Here is one person's solution: 1979 Ford F150 4x4 - 1979 F-150

Also, a 2wd ZF is fixed rear yoke, so you will need to get a 2 piece driveshaft if you don't already.

You also need to build a custom rear tranny mount, as the ZF rear mount is further back than anything 73-79 had.

I'm still (7 years and counting) in the parts gathering stage of my 2wd ZF swap with 351W.

 

when i installed the ZF in mine i drilled out the alignment hole between the two mounting holes on top of the frame, and drilled the rest once i bolted that one up, took my mount and pedestool off my old trans and bolted it right to the ZF works great. As far as clutch goes, pretty simple, though a pain in the ****. I took the hydraulic clutch rod and pedal and my old pedal and pedal assembly into the machine shop and had him machine part of the shaft down to go into my assembly. Had my clutch pedal machined off and slotted to fit the newer shaft. it would be the left side of the shaft that gets machined down and then you slide it thru and bolt on the pedal, once the pedal is in place, the unmachined part of the shaft will keep it from walking back and forth, as you need the extra length to place the clutch master where it wont hit the brake booster. once the shaft is in, mark where the master cylinder link is on the firewal and drill it out. bolt on the MC and done, very smooth, and softer clutch. I also used the newer softer spring. I cant remember why i used the old pedal but it was for a reason, you may want to pick one up. Im pretty sure the clutch shaft holes are in the auto assemblies as well. I can try and get pics if you need them. BTW, i would get a quote, the shop i went to charged $70 bucks, where as i thought it should be in the 30-40 dollar range.

 

Thanks for the info, I would love to see the pictures. Did you have any problems with the clutch or flywheel? I have the flywheel and balancer from a doner 302.

 

There is at least one member that grafted his clutch fork to the ZF5 fork for a neat install without using a hydraulic setup. I would advise you to make a reinforcement plate for the firewall inside the cab to spread the pressure of the master cylinder. I am not sure about the gas clutches but the diesel clutches takes enough pressere the firewall will eventually crack.

 

The 302 and 351W doesn't use a lever, it uses an expansion throwout for a slave. The 460 and the diesel version have the lever.

 

http://www.panix.com/~alvinj/file12/7A621.jpg
Sorry the picture is blurry, took it quick, in the pitch black, for a guy. LOL :)
Something I need to try again and copy over the top of it.

Anyway, that's the "part number" 7A621 ...without the prefix or suffix.
That part came in the '90 F250 parts truck, I moved it to the '91 Bronco.
The '91 Bronco was originally E4OD-ed up {ick} and I ZF-ed it. ;)

And that's the simple part Ford put in the vehicles new and it worked.
Other parts are retro-fit for firewalls that are damaged from not having it.
That beat-up '90 parts truck had 188k on it and was a "company truck".
So it really was treated bad at times and the firewall on it is fine! :)

But check out the wimpy clutch-pushrod Ford used tho...
http://www.panix.com/~alvinj/file12/pushrods.jpg
...what a piece of Ford crap, huh? :/
That's the matching stud there with it.

Made my own stud and replaced it with a brake push rod. :)
The big yellow one, pictured there, is a brake pushrod.
The new silver one is what came with the new clutch-master cylinder.

This is after shortening and rounding off the end of the brake pushrod...
http://www.panix.com/~alvinj/file12/pushrod.jpg

This isn't roK-Ket science, you just have to put your share of time in
"standing on your head" and you'll get-'er done no sweat. ;)

Alvin in AZ
ps- Oh crap. :( ...Just realized this ain't in the '87 to (whatever) forum.