Transmission swap to ZF5 - Ford Bronco Forum
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post #1 of 39 (permalink) Old 09-29-2011, 12:26 AM Thread Starter
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Bronco Info: '94 XLT 302 /ZF5 speed /35"s/Custom Rock Sliders/Limited Slip Rear/Lead Foot/8000#Winch
Cool Transmission swap to ZF5

OK so my Mazda M5OD manual trans started to hum and wherr and become hard to get into reverse and first gear,vibrate between 4th and 5th(OD) gear......and to think it only has 201,683.0 miles on it........and when I'm wheeling, I beat the hell out of it....so it's finally worn out.
I did the due dillegence and found a good company to buy a rebuilt ZF5 transmission from..........decent price.....decent shipping price....the correct ZF trans......so I bought it.
I started my install today.....I will post pics after I get it completely installed and let you know if I have any problems.
Stay tuned....

I wrench on it because I have to....
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post #2 of 39 (permalink) Old 09-29-2011, 03:01 AM
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Quote:
Originally Posted by oldrojo View Post
OK so my Mazda M5OD manual trans started to hum and wherr and become hard to get into reverse and first gear,vibrate between 4th and 5th(OD) gear......and to think it only has 201,683.0 miles on it........and when I'm wheeling, I beat the hell out of it....so it's finally worn out.
I did the due dillegence and found a good company to buy a rebuilt ZF5 transmission from..........decent price.....decent shipping price....the correct ZF trans......so I bought it.
I started my install today.....I will post pics after I get it completely installed and let you know if I have any problems.
Stay tuned....
awsome dude

BIG BABIES!!!
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post #3 of 39 (permalink) Old 09-29-2011, 08:41 AM
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yo,
It would be goo to post the install in the Tech Section;
I have some Install LINKs in my site @ http://www.broncolinks.com/index.php?index=55
such as (Hot Links for all are there)

S5-42 Swap from E4OD in a 95
Source: by Broncobabe (Miss Kitten)

S5-42 Swap from E4OD in a 93
Source: by lifeizhard102205 at FSB

S5-42 Swap from E4OD Parts List in a 94
Source: by Franklin (Jeff) at FSB

S5-42 Shifter Parts Diagram
Source: by Steve83

S5-42 (7003) Parts Break-Out Diagram, Service Tips & Troubleshooting Guide; 07-03B-17 1994 Econoline / F-150, F-250, F-350 / Bronco / F-Super Duty Powertrain, Drivertrain Aug 1993
S5-42 Troubleshooting Guide TSB 90-15-11 for 87-91 BRONCO, F & E Series
Source: by Ford

S5-42 (7003) Disc, Pressure Plate & Slave Cylinder Replacement & Parts Break-Out Diagram in 96 Bronco & F-150, F-250, F-350, F-Super Duty Chassis Cabin 96 Bronco & F-150, F-250, F-350, F-Super Duty Chassis Cab
Source: by Ford

S5-42 Tips; "...There are three rubber plugs on top of the transmission that leak fluid only when the truck is in motion so when parked there will be no tell tail signs of a leak. You can replace the plugs yourself or take it to the dealer and have them check it for fluid lose and replace the faulty plugs but it's not cheap. Thing is, the seals are going to fail and if caught to lateas in my case cost you a bundle. Another set back for theback yard mechanic is the bleeding of the slave cylinder. If not done exactly correct your clutch will not work no matter how much you bleed it. Bleeding the slave cylinder, which is inside the transmission and not on the outside like older ones, relies more on gravity to bleed and not pumping. It's just a big pain in the ass actually and it will test your patience.
Source: by WooleyBugger at wooleysrant.blogspot.com

ZF S5-47 Diagnosis & Testing,Overview & Parts Break-Out Diagram, Service Tips & Troubleshooting Guide
Source: by ZF

ZF, all ZF Loctite Sealant Usage TSB 94-17-13 for Vehicles Built From 2/2/94

GL!

96 XL 5.0 E4OD, Man Xfer/Hubs
USN & DoD Planner (ret)
THANKS to ALL WHO SERVE!

my broncolinks.com was "disturbed"; but some sections are archived @ [url]http://web.archive.org/web/20121009110424/http://www.broncolinks.com/index.php
select a LINK, Right Click & Hit Properties; copy the second HTTP address; paste in a new browser window or Tab to see original page


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post #4 of 39 (permalink) Old 09-29-2011, 09:28 AM Thread Starter
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Cool

Thanks Miesk5,
I needed the fluid chart to verify which Mercon fluid to put in my ZF!!!

thanks for the links!!

I wrench on it because I have to....
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post #5 of 39 (permalink) Old 09-30-2011, 07:54 AM
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yw,
GL and hope to see the pics & narrative soon so I can include it in my site for others to use.

96 XL 5.0 E4OD, Man Xfer/Hubs
USN & DoD Planner (ret)
THANKS to ALL WHO SERVE!

my broncolinks.com was "disturbed"; but some sections are archived @ [url]http://web.archive.org/web/20121009110424/http://www.broncolinks.com/index.php
select a LINK, Right Click & Hit Properties; copy the second HTTP address; paste in a new browser window or Tab to see original page


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post #6 of 39 (permalink) Old 09-30-2011, 10:09 AM
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Excellent! I look forward to seeing your progress!
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post #7 of 39 (permalink) Old 09-30-2011, 11:01 AM
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I have wanted to see this write up for a while as I am sure to have this problem sometime. But I only have 118k on mine. So I can hope, not sure if I am hoping to need to replace or to keep the M05. I would love to see a round scale pricing as well.

Always topless
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post #8 of 39 (permalink) Old 09-30-2011, 12:30 PM
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Quote:
Originally Posted by Sock Puppet View Post
Excellent! I look forward to seeing your progress!
same here

-Michael
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post #9 of 39 (permalink) Old 09-30-2011, 01:46 PM
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Originally Posted by rcracerx View Post
awsome dude
Burque's are just that way. LOL

-------------------------

Ol'Jo, you gonna use an engine hoist?



I made the mistake of putting the rear chain too far back and it bumped
into the sheet metal at the rear and had to move it forward while-trying
to lift it and so did a sloppy job of moving it.

Next time I'll put the rear chain that far back like it is there, except behind
the drain plug. See it? :) It's obvious as anything while dropping one but
not as obvious when lifting a different model into place. LOL :)

Also do yourself a big favor and make a set of these, made mine in '79...


7/16" coarse thread ~6" long, you don't need to dog nose 'em like I did.

See one in action up there? The ZF slid up to there with a simple push of
a foot, no wrestling it into place trying to get it to line up etc. Pins work
great while pulling one by yourself too.

I made another about a 1/2" shorter that I haven't used yet.
Do that. Make 'em about a 1/2" different in length.

Gonna make another short one and give a set to my son, he's got a '75
F250 "farm truck" going for the fun of it, that was given to me for parts.

With an engine hoist and those pins, it's an easy one man operation!

Alvin in AZ
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post #10 of 39 (permalink) Old 09-30-2011, 02:35 PM
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I'm interested to hear how you like the shift feel and ratios of the M5R2 vs the ZF.
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post #11 of 39 (permalink) Old 09-30-2011, 03:02 PM
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Quote:
Originally Posted by Philofab View Post
I'm interested to hear how you like the shift feel and ratios of the M5R2 vs the ZF.
I have the ZF in my bronco now and had the m5 in a 4.0 ranger. I can tell you this the only feeling that is even close between the two is the shift knob. First gear is only good for crawling. To much of a jump between 1st and 2nd to use regularly. So now you have three speed with overdrive. I drive a lot of city type driving. Once moving with a 351w, 33's and 3.54's I am in 3rd and 4th lot from 15-60mph until the roads open up. The ranger I could use a lot more of the gears because they were closer together. My engine doesn't care if lug it down below 1000 rpm and accellerate. It is not a performance feeling trans, it is a truck tranny.


77 Scout SSII 460 c6/np205 Dana 60/14blt H2 wheels 36 Irok radials
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post #12 of 39 (permalink) Old 09-30-2011, 03:57 PM
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Quote:
Originally Posted by Brochoncho View Post
It is not a performance feeling trans, it is a truck tranny.
x2 :)

I test drove a Bronco 300i6 with the Mazda and felt like 1st was too low
and 2nd too high when starting from a stop. :/ With the ZF, 2nd is a little
too high with 32" tires and 3.55 gearing and 351w even with the cam
timing advanced 4 degrees. YMMV on that one?

I snugged up my ZF inside to make it as tight as I could while I had it apart
and still it feels like a car transmission shifter compared to my T18 in the
'75 F150. But, the ZF shifts slower than the T18 IME. Guessing that's
because the ZF's got bigger+heavier gears in it. Don't remember actually
-liking- the Mazda in any way! LOL :)

Anyone that wants to snug up the shifter on a ZF let me know, I worked
out a couple things that took some time to figure out. You'll need it off
there first, too hard to describe otherwise.

-------------------------

I just plain ol' needed the ZF's pattern, it's the same as my T18 I've had
since I was 22. Cars needing the left and up to start, messes me up kinda.

Alvin in AZ
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post #13 of 39 (permalink) Old 09-30-2011, 11:43 PM
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From what your telling me I want to put one of my extra M5R2s in my F250 behind the 5.9 instead of a ZF.
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post #14 of 39 (permalink) Old 10-01-2011, 02:40 AM
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Quote:
Originally Posted by Philofab View Post
From what your telling me I want to put one of my extra
M5R2s in my F250 behind the 5.9 instead of a ZF.
What F250? :/

...and just how big of a pile of M5R2s you got? LOL :)

Alvin's dumber than we all thought in AZ
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post #15 of 39 (permalink) Old 10-01-2011, 02:32 PM
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Quote:
Originally Posted by Alvin in AZ View Post
What F250? :/

...and just how big of a pile of M5R2s you got? LOL :)

Alvin's dumber than we all thought in AZ
I have an 86 F250 with a Cummins swap. It currently has a C6 / gear vendor.

I have three M5R2s right now. One is in my 93 Bronco, and the other two are spares since I only get about a year of use out of them the way I use my Bronco.
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post #16 of 39 (permalink) Old 10-01-2011, 03:49 PM
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Quote:
Originally Posted by Philofab View Post
I have an 86 F250 with a Cummins swap. It currently has a C6 / gear vendor.

I have three M5R2s right now. One is in my 93 Bronco, and the other two are spares since I only get about a year of use out of them the way I use my Bronco.
Mazda tranny go BOOM with anything more than a stock 302.
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post #17 of 39 (permalink) Old 10-01-2011, 04:06 PM
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My M5OD has been holding up well to my built 351

BIG BABIES!!!
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post #18 of 39 (permalink) Old 10-01-2011, 04:27 PM
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Bronco Info: 95 ford bronco, 5.0L V8, M5OD trans, manual BW 1356, Warn Premium hubs
my m50d is junk and its behind a 302. Its been rebuilt once befor at least i think cause theres a plate attached to the bell housing, and the trucks only got 125k on it. Im hoping it lasts untill the new year, then its zf swap time for me.
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post #19 of 39 (permalink) Old 10-01-2011, 06:16 PM
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Quote:
Originally Posted by Swat View Post
Mazda tranny go BOOM with anything more than a stock 302.
My issue has been with the re builders work so far. I bought my Bronco with a bad trans due to an oil leak. I had it rebuilt and 40K later the forks gave way from not being replaced. Nothing has ever gone "boom" and my motor is not stock. I run 35" tires, 9", Detroit, and have destroyed a 9" case, two drivelines, and a ring+pinion.

If my new roller 351w is too much for it I will go to a custom viperized T-56 setup. The ZF gear ratios just don't suit my use of the truck. I hear it's loud too which will make longer drives even less bearable.
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post #20 of 39 (permalink) Old 10-02-2011, 02:01 AM
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I've only had my 351 in for a year, but I do wheel in pretty good when I get a call out for search and rescue

BIG BABIES!!!
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