ZF5 or NP435 and a doubler in a 79 Bronco? - Ford Bronco Forum
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post #1 of 21 (permalink) Old 12-30-2013, 11:26 PM Thread Starter
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Bronco Info: 1979 Bronco, 4" lift, 35" tires; UPGRADING: ZF5, 468 BBF, NP203/NP205 Doubler, Hydroboost, etc
ZF5 or NP435 and a doubler in a 79 Bronco?

Next year I am planning to get the slushbox taken out of my 1979 Bronco (466 engine) and replaced with a manual transmission. I have a NP435 (which needs to be finished rebuilding) and a 460 ZF5 S-42 that I have gotten (don't know to history of it). I also have a NP203 transfer case in my Bronco (was supposedly converted to Part time) and I also have a NP205 transfer case and was first thinking of just putting the NP205 in my Bronco and twin sticking it but now I was thinking since I have this NP203...I could just take the range box and get the NP205 and get a doubler adapter from JEDS to have a doubler.

The Bronco will be used to drive me to work sometimes when I'm not driving my motorcycle and will be used to go offroad and tow some.


QUESTION IS

Should I do the ZF5 or the NP435?
Should I just use the NP205 or should I make a doubler?
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post #2 of 21 (permalink) Old 12-31-2013, 11:46 AM
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By a doubler, are you meaning something like a Gear Vendors? An extra unit that you attach between the transmission and transfer case that makes your 4spd an 8spd?

If so, from what I've read, the Bronco is simply too short for one of these units. The rear drive shaft would be shortened too much and the angle put on the joints would cause them to prematurely wear out. I don't think there's any way to get around it, either.


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post #3 of 21 (permalink) Old 12-31-2013, 11:47 AM
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I think the zf5 is gonna be to long for a bronco
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post #4 of 21 (permalink) Old 12-31-2013, 12:01 PM
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Originally Posted by Nvrsatisfied84 View Post
I think the zf5 is gonna be to long for a bronco
There's lots of Broncos with ZF5s in them.


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post #5 of 21 (permalink) Old 12-31-2013, 12:39 PM Thread Starter
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Bronco Info: 1979 Bronco, 4" lift, 35" tires; UPGRADING: ZF5, 468 BBF, NP203/NP205 Doubler, Hydroboost, etc
Doubler is two transfer cases that are together that provide a lower gear ratio. Like the np203 and np205 adapted together behind the transmission.
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post #6 of 21 (permalink) Old 12-31-2013, 12:55 PM
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I think the zf5 is gonna be to long for a bronco
There is not a significant difference in length between a ZF and a C6.

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post #7 of 21 (permalink) Old 12-31-2013, 02:45 PM Thread Starter
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There is not a significant difference in length between a ZF and a C6.
How do you have your ZF5 in yer 78
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post #8 of 21 (permalink) Old 01-01-2014, 12:24 PM
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its the BW transfercase that adds the length to the combo, a ZF and a 205 work great together.
I would put the ZF with the 205 in and see how much room you have then add the doubler if you have the room

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post #9 of 21 (permalink) Old 01-01-2014, 02:14 PM
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the ZF 5 speed length from front of bell housing to end of tail adapter is within a inch of a np435/t18 length from front of bell housing to end of tail adapter as with the short shaft
C6 that was used in the 203 trucks

so by adding a doubler you can add that length to the over all length making for a rather short rear drive shaft
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post #10 of 21 (permalink) Old 01-01-2014, 02:27 PM Thread Starter
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Think it will be too short even with a 6" lift? I got an ORD zero rate in which I may can move the axle back 1-1.5".
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post #11 of 21 (permalink) Old 01-01-2014, 02:30 PM
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the lift will make for a steeper angle on that shorter distance making the problem worse
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post #12 of 21 (permalink) Old 01-01-2014, 09:44 PM
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I was thinking the zf5 was like 4ish inches longer from front bell housing to transfer case flange so with the doubler it would leave a super short rear shaft length
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post #13 of 21 (permalink) Old 01-01-2014, 10:38 PM Thread Starter
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Well I'm going to just run the ZF5 and NP205 for now...we'll check on the doubler later.
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post #14 of 21 (permalink) Old 01-02-2014, 11:52 AM
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How do you have your ZF5 in yer 78
The ZF will bolt right up to your 460 and 205, but you'll have to modify your trans crossmember or build your own. I went ahead and made my own.

Edit: the intermediate housing will have to be notched for the 205 linkage, but that takes all of 2 careful minutes with a grinder.

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Last edited by chebbykiller; 01-02-2014 at 11:53 AM. Reason: add info
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post #15 of 21 (permalink) Old 01-02-2014, 12:05 PM
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if the truck is used more for street driving I would use a zf5. If its used more for off road then I would use a np435. I blew out reverse and 3rd in my zf5 shortly after I welded the rear end but i also got a better DD so I no longer needed overdrive and wanted a granny gear so the np435 was an obvious choice. I love the zf5 for a street truck but for a hardcore wheeler I am personally just not a fan.
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post #16 of 21 (permalink) Old 01-02-2014, 12:08 PM
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Let me tell you from experience and owning trucks with both:

If you are running a doubler you will have no need for the NP435. If you are running a single transfer case than the 6.30'some ratio of the first gear granny low will be helpful.

It would also be nice if you told us what you were planning on doing with the truck, what tire size, and what gear ratio you were running.

If you run a doubler, you are better off with a ZF5 speed transmission for the better gas mileage, since you are easily able to double your low range twice over (each transfer case) With the NP435 you will have no added benefits, just basically the loss of 2 gears, and worse gas mileage.

Also, the ZF5 and a 205 will do fine for mudding and basically any and all terrain. Even rock crawling. Unless you need incredibly low gearing the NP435 or the doubler won't do you much good.


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post #17 of 21 (permalink) Old 01-02-2014, 06:04 PM Thread Starter
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Bronco Info: 1979 Bronco, 4" lift, 35" tires; UPGRADING: ZF5, 468 BBF, NP203/NP205 Doubler, Hydroboost, etc
Quote:
Originally Posted by chebbykiller View Post
The ZF will bolt right up to your 460 and 205, but you'll have to modify your trans crossmember or build your own. I went ahead and made my own.

Edit: the intermediate housing will have to be notched for the 205 linkage, but that takes all of 2 careful minutes with a grinder.
You use the hydraulic clutch? If so, how did you hook it up?



Quote:
Originally Posted by mantooth View Post
if the truck is used more for street driving I would use a zf5. If its used more for off road then I would use a np435. I blew out reverse and 3rd in my zf5 shortly after I welded the rear end but i also got a better DD so I no longer needed overdrive and wanted a granny gear so the np435 was an obvious choice. I love the zf5 for a street truck but for a hardcore wheeler I am personally just not a fan.
Its gonna be a street/weekend toy. I will also tow with it some.

If the ZF5 kicks the bucket....I may just put the NP435.


Quote:
Originally Posted by Smok3y View Post
Let me tell you from experience and owning trucks with both:

If you are running a doubler you will have no need for the NP435. If you are running a single transfer case than the 6.30'some ratio of the first gear granny low will be helpful.

It would also be nice if you told us what you were planning on doing with the truck, what tire size, and what gear ratio you were running.

If you run a doubler, you are better off with a ZF5 speed transmission for the better gas mileage, since you are easily able to double your low range twice over (each transfer case) With the NP435 you will have no added benefits, just basically the loss of 2 gears, and worse gas mileage.

Also, the ZF5 and a 205 will do fine for mudding and basically any and all terrain. Even rock crawling. Unless you need incredibly low gearing the NP435 or the doubler won't do you much good.
35x12.50x15 tires. Probably run 4.10 or 4.56 gears.

Truck as mention will be for street/occasional off road/tow.
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post #18 of 21 (permalink) Old 01-02-2014, 07:58 PM
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You use the hydraulic clutch? If so, how did you hook it up?
Yes. I cut the holes in the firewall for the master cylinder and drilled a hole in the clutch pedal for the cylinder pushrod. It's pretty straight-forward. Here are some pics: http://www.supermotors.net/registry/16969/80819

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post #19 of 21 (permalink) Old 01-02-2014, 10:38 PM Thread Starter
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Cool thanks.

I see you didn't use the brake booster though and I will..hmm..
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post #20 of 21 (permalink) Old 01-02-2014, 10:51 PM
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Yeah, had I mounted it a little bit lower if may have cleared the booster. The brakes don't feel drastically different without the booster, so all is well until I get around to installing my hydroboost.

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