ZF5 swap question - Ford Bronco Forum
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post #1 of 20 (permalink) Old 05-18-2017, 04:35 PM Thread Starter
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ZF5 swap question

Ive got a lead on a 88 or 89 f250 with the smallblock zf trans. Ive got a 96 f350 with a puking c6. I want overdrive, and love shifting through the gears.

My main question is this: has anyone succesfully modified a 87-91 pedal assembly to work in a 92-96? I know its not bolt in because of the differences under the dash. Ive read a couple threads and came up with nothing. I cant imagine that its not capable of being altered to work. Thoughts?

94 Bronco XLT. Beefy 351, 6" , 37's, 4.88: burnt
85 Bronco custom, 4" 37's, locked 4.56, 300 i6 4 bbl, np435/208
96 f350 XL, rclb, 351, c6, BW4407 xfer
78 f150 Ranger, 351m, t18, np205, rusty
90 f150, 95 f250, 96 f350 psd: stolen, sold, and burnt, respectively.
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post #2 of 20 (permalink) Old 05-18-2017, 04:54 PM
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There was a guy on here recently who made a 92-96 assembly work in his brick nose, but it was a stupid amount of work and harness splicing. Why wouldn't you just use the correct year assembly for your truck?

Here's that thread:

5 speed conversion.
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post #3 of 20 (permalink) Old 05-18-2017, 05:03 PM Thread Starter
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Originally Posted by Dman94X View Post
There was a guy on here recently who made a 92-96 assembly work in his brick nose, but it was a stupid amount of work and harness splicing. Why wouldn't you just use the correct year assembly for your truck?

Here's that thread:

5 speed conversion.
Cool ill read over that, thanks. Just didnt want to have to source a set of pedals when the donor has pedals. But if its too much of a hassle, then id have to just find some from a 92-96/7. Bad thing is the nearest pick and pull is a 90+ minute drive to KC, one way. Salvage yards here in topeka, are crazy expensive and carry mostly cars and newer stuff.

94 Bronco XLT. Beefy 351, 6" , 37's, 4.88: burnt
85 Bronco custom, 4" 37's, locked 4.56, 300 i6 4 bbl, np435/208
96 f350 XL, rclb, 351, c6, BW4407 xfer
78 f150 Ranger, 351m, t18, np205, rusty
90 f150, 95 f250, 96 f350 psd: stolen, sold, and burnt, respectively.
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post #4 of 20 (permalink) Old 05-18-2017, 05:05 PM
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Originally Posted by BigBlue 94 View Post
Cool ill read over that, thanks. Just didnt want to have to source a set of pedals when the donor has pedals. But if its too much of a hassle, then id have to just find some from a 92-96/7. Bad thing is the nearest pick and pull is a 90+ minute drive to KC, one way. Salvage yards here in topeka, are crazy expensive and carry mostly cars and newer stuff.
I usually pull and sell 2/3 sets of 92-96 pedal assemblies a week. If you need one I can hook you up.
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post #5 of 20 (permalink) Old 05-18-2017, 05:17 PM
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Use car-part.com and see if anyone has some they will ship?
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Dylan

1992 XLT 300/M5OD
1978 Custom 351M/C6
1991 XLT 351W/Blown Up E4OD
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post #6 of 20 (permalink) Old 05-18-2017, 05:53 PM Thread Starter
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Originally Posted by Dman94X View Post
I usually pull and sell 2/3 sets of 92-96 pedal assemblies a week. If you need one I can hook you up.
Just read through that thread, definitely doesnt seem worth that hassle. If the kid wants to sell me the truck, ill PM you about the pedals. Thanks
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94 Bronco XLT. Beefy 351, 6" , 37's, 4.88: burnt
85 Bronco custom, 4" 37's, locked 4.56, 300 i6 4 bbl, np435/208
96 f350 XL, rclb, 351, c6, BW4407 xfer
78 f150 Ranger, 351m, t18, np205, rusty
90 f150, 95 f250, 96 f350 psd: stolen, sold, and burnt, respectively.
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post #7 of 20 (permalink) Old 05-18-2017, 07:53 PM
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I also have 2 sets of 92-96 pedals, plus a line on a few more.

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post #8 of 20 (permalink) Old 05-19-2017, 06:29 PM
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Bigblue,

I thought this over for a long time as I am ramping up my C6 to ZF swap here in the next couple of weeks. I HIGHLY recommend that you simply look for a donor truck. Every single piece (minus the custom driveshaft) will be already available on a donor.

Then on top of that if you want to put the work in, you can install the auto into the donor truck and sell it like that. Make some, all or possibly even MORE money than what you payed for donor. A win-win situation, considering how much more expensive it would be to source EVERY single part needed for the swap.

Oh and to answer your first question, yeah, don't **** around with a different generation of truck. Potentially too much fab work required.

"Oh man, lodged where??"
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post #9 of 20 (permalink) Old 05-19-2017, 08:40 PM Thread Starter
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Definitely looking for a donor truck. The reason i am considering this truck is its a running driving truck, with a 351 with some sort of 302 heads. I think they are gt40s. The trans has just been gone through, at least far enough to replace the internal slave. I could find a use for that engine, and my spare d60 front needs a matching 10.25, so id like to keep that for my 78 f150. If the engine in the 78 is toast (sitting 15+ years), i could swap in the windsor and c6. Basically, id rather part out the donor, than sell it as a driver. I could also use a pickup bed trailer for a camping trailer...

Ive got too many projects! And not enough time.
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94 Bronco XLT. Beefy 351, 6" , 37's, 4.88: burnt
85 Bronco custom, 4" 37's, locked 4.56, 300 i6 4 bbl, np435/208
96 f350 XL, rclb, 351, c6, BW4407 xfer
78 f150 Ranger, 351m, t18, np205, rusty
90 f150, 95 f250, 96 f350 psd: stolen, sold, and burnt, respectively.
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post #10 of 20 (permalink) Old 05-19-2017, 10:05 PM
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Quote:
Originally Posted by BigBlue 94 View Post

Ive got too many projects! And not enough time.
Story of my life.

"Oh man, lodged where??"
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post #11 of 20 (permalink) Old 05-19-2017, 10:40 PM
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I thought that the driveshaft lengths were the same over the years(given they were the same transmission/axle configuration). Although, it might be a moot point since the f350 would have a d60 front and the f250 would have a d50. The only things that were different between the generations I think were the pedal assembly, maybe the shifter and/or shifter boot, and maybe master cylinder/hose. Not too sure about that though.
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post #12 of 20 (permalink) Old 05-20-2017, 02:33 PM
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@mrnewland1 and @sharpshooter109 the driveshaft should be able to be swapped over AFAIK, both trucks almost certainly have the 10.25, and the trans should be in the same position

Tough to kill an old six
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post #13 of 20 (permalink) Old 05-21-2017, 08:43 AM
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@sharpshooter109 and @I6-Kid I hope you guys are right because that would mean basically all I would have to do for the swap is buy some new fluid for the ZF and for the C6.

But I fear that something will not line up, that's just my luck, besides I do remember reading older posts about this topic and the people mentioning thay had to lengthen/shorten their front/rear driveshafts.

I plan on doing a youtube series on the highlights of the swap, as I have not found any exactly like I'm doing for the 4th generation Broncos.

"Oh man, lodged where??"
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post #14 of 20 (permalink) Old 05-21-2017, 10:20 AM
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I think what @I6-Kid is saying is that the driveshafts stay with the transmission. What I mean by that is that @BigBlue 94 would use the driveshafts from the f250 (zf5) in the f350 with the zf5 trans. There are 2 factors that determine if the f250 driveshafts will work. #1 is the length. This is determined by the cab/bed configuration and by the axle. For instance, a 10.25 has a longer yoke than an 8.8 so the 10.25 uses a shorter driveshaft than an 8.8 would. Obviously it would be impossible to find a zf5 rear driveshaft that would fit a bronco, but I hear that the m5od front and rear driveshafts for a bronco would work with a zf5 in a bronco. #2 is the flange/yoke on the axle on the f350. Obviously the driveshaft has to bolt up to the axle so they've got to be the same size flange or the same size u-joint if it uses a yoke. I'm not sure what axles the f350 has, and I'm not sure what the driveshaft differences would be even if I did know, but hopefully this will give you enough info to figure it out.
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post #15 of 20 (permalink) Old 05-21-2017, 10:38 AM Thread Starter
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Both trucks are single cab long beds. Mine has d60 / 10.25. F250 has d50 /10.25.

Ive seen a thread here where they used an excursion front drive shaft on the rear of a bronco. Im sure i can make one of mine work. The f350 has a near brand new driveshaft on the rear. Keep in mind that the c6 is a bit shorter than an e4od that comes in most broncos of this era.

Im gonna ask this before researching, but will my beefier bw44-07 transfer case bolt in place of the bw13-56 thats on the zf? I dont figure many people here have any experience with the 44-07 as it never came in a bronco and only in f350 for a couple years. Mine is manual shift, and i can only assume the f250 has manual shift.

94 Bronco XLT. Beefy 351, 6" , 37's, 4.88: burnt
85 Bronco custom, 4" 37's, locked 4.56, 300 i6 4 bbl, np435/208
96 f350 XL, rclb, 351, c6, BW4407 xfer
78 f150 Ranger, 351m, t18, np205, rusty
90 f150, 95 f250, 96 f350 psd: stolen, sold, and burnt, respectively.
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post #16 of 20 (permalink) Old 05-21-2017, 10:42 AM
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Quote:
Originally Posted by BigBlue 94 View Post
Im gonna ask this before researching, but will my beefier bw44-07 transfer case bolt in place of the bw13-56 thats on the zf? I dont figure many people here have any experience with the 44-07 as it never came in a bronco and only in f350 for a couple years. Mine is manual shift, and i can only assume the f250 has manual shift.
To my knowledge, any ford transfer cases from 80-96 could be swapped with no modification

Tough to kill an old six
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post #17 of 20 (permalink) Old 05-21-2017, 10:49 AM Thread Starter
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Thats kind of what i was thinking. Thanks

94 Bronco XLT. Beefy 351, 6" , 37's, 4.88: burnt
85 Bronco custom, 4" 37's, locked 4.56, 300 i6 4 bbl, np435/208
96 f350 XL, rclb, 351, c6, BW4407 xfer
78 f150 Ranger, 351m, t18, np205, rusty
90 f150, 95 f250, 96 f350 psd: stolen, sold, and burnt, respectively.
BigBlue 94 is online now  
post #18 of 20 (permalink) Old 05-21-2017, 10:58 PM
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Keep in mind the shift linkage for the bw44-07 may need to be modified as the t-case will be further forward with the shorter trans. There may be enough room though.
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post #19 of 20 (permalink) Old 05-30-2017, 10:29 AM Thread Starter
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Looks like its a go! Truck has 351 w gt40 heads, long tube headers, and some body rust in the usual spots. Its an 88 f250 4x4 rclb. Has a massive brush guard on the front and a decent headache rack.

The zf shifts good, and has new clutch, slave cyl, throw out bearing, and flywheel. This is all a huge plus in my eyes. Overall the truck is in good mechanical shape, with the only noticable leaks being the valve covers.

He wants a bit more than id like to pay, but the new trans parts help cover that. Between the cost of those, and what it would cost to rebuild my current c6, the truck will basically be paid for
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94 Bronco XLT. Beefy 351, 6" , 37's, 4.88: burnt
85 Bronco custom, 4" 37's, locked 4.56, 300 i6 4 bbl, np435/208
96 f350 XL, rclb, 351, c6, BW4407 xfer
78 f150 Ranger, 351m, t18, np205, rusty
90 f150, 95 f250, 96 f350 psd: stolen, sold, and burnt, respectively.
BigBlue 94 is online now  
post #20 of 20 (permalink) Old 06-01-2017, 02:30 PM Thread Starter
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Got the 88 donor f250 home. Runs pretty darn well and shifts real nice. Lots of good usable hard parts. Swap thread will be coming in the near future.




94 Bronco XLT. Beefy 351, 6" , 37's, 4.88: burnt
85 Bronco custom, 4" 37's, locked 4.56, 300 i6 4 bbl, np435/208
96 f350 XL, rclb, 351, c6, BW4407 xfer
78 f150 Ranger, 351m, t18, np205, rusty
90 f150, 95 f250, 96 f350 psd: stolen, sold, and burnt, respectively.
BigBlue 94 is online now  
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