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Old 02-18-2013, 11:26 AM   #1
TheBlackDevil
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C6 to ZF5 swap

I have decided to put the C6 to the curb since my Bronco is my DD. I got a 460 ZF5 I need to put in it. I have a 460 I am going to put in and the ZF5 is the way to go.


I have some questions though I did do research on it. Not many people have done this on our Broncos.

1) Can I use my current trans crossmember? Will it have to move?

2) Will I have to shorten or lengthen my driveshaft? (Heard people say the stock shaft will work)

3)What clutch assembly and linkages would i need or do I have to make them?

4)Also I plan to run a Borg Warner transfer case. Will driveshaft still work?
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Old 02-18-2013, 01:27 PM   #2
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Bronco Info: 1996 351w np435 swap, long arm sas, shackle flip 9" swap, 36" TSL Super Swampers grooved
1)You are probably better off just making a new cross member although the factory one will probably work it will just have to be relocated.
2)My guess would be yes you will have to get your driveshafts redone. when I swapped out the e4od for a zf5 my rear was quite a few inches too short.
3) you will need to go to the junkyard and get a pedal assembly for a manual f150 for your year of bronco. in my 96 I needed one from a 92-96 bronco.
4)I am not sure what ujoints your current driveshafts run but they make conversion joints so I wouldn't be worried.
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Old 02-18-2013, 04:03 PM   #3
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Bronco Info: 1974 Bronco with 351w, 1978 F150 4x4 with 1966 F100 cab
ZF

My buddy did this on his 78 Bronco with a 460. Used a BW 1345 transfer case, custom driveshafts, body lift to clear the ZF, modified the stock crossmember. I have a few pictures. If I go back by there I will take pictures of the crossmember.
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Old 02-18-2013, 05:00 PM   #4
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Thank you! Give me some pictures of clutch linkages! I dont know about a body lift...ugh..
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Old 02-18-2013, 05:28 PM   #5
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Bronco Info: 1996 351w np435 swap, long arm sas, shackle flip 9" swap, 36" TSL Super Swampers grooved
You will have to either do a body lift or hack up the trans tunnel cover from what ive seen
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Old 02-18-2013, 06:23 PM   #6
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Bronco Info: '91 RoadQueen 351w-2wd-ZF camtiming+4* 265/75-16E's dual Ranchos F&R, SuperCab bench seat EEC=F250
Sam's got the right idea! :) (post #7)

Quote:
Originally Posted by mantooth View Post
You will have to either do a body lift or hack up the trans tunnel cover from what ive seen
Really? :/
You can't cut it nice?
You really have to hack it up? ;)

The ZF might be tall but its gearshift lever is a dinky little shit...
(T18 middle, ZF bottom)

...so if you do a body lift (ick) you'll be bent over ev'rytime you shift and wreck. ;)


Or you could hack-up ;) the original ZF lever and add some length to it...


^19/32" drill bit ~= 15mm

It'd be better to weld up one, I had the '75 C700 lever and wanted to use it is all. xD

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Old 02-18-2013, 07:01 PM   #7
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Bronco Info: 1978
the shift lever is shorter but the tower is quite a bit taller.
when i did mine i cut off the stock ZF shifter and welded on a 4spd shifter so i could put it right where i wanted it.
i also built my own crossmembers and used the NP205.
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Old 02-19-2013, 12:02 AM   #8
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Well what I thought was a BW1356 case that the guy I got the Bronco from gave me, is actually a NP208 aluminium transfer case.
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Old 02-19-2013, 03:28 AM   #9
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Bronco Info: 1996 351w np435 swap, long arm sas, shackle flip 9" swap, 36" TSL Super Swampers grooved
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Really? :/
You can't cut it nice?
You really have to hack it up?
Nope hacking is honestly the only option.
Trust me, I have done 1 zf5 swap so im obviously an expert.
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Old 02-19-2013, 10:39 AM   #10
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On a 1996 Bronco but not on a 78-79 Bronco.
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Old 02-19-2013, 05:02 PM   #11
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Quote:
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Nope hacking is honestly the only option.
Trust me, I have done 1 zf5 swap so im obviously an expert.
LOL :)
Same here but mine was a super-simple 2wd ZF swap. :/
So what sort of -armchair- expert does that make me? :)
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"On a 1996 Bronco but not on a 78-79 Bronco." -TheBlackDevil
I too lost track of that point, TBD. :)

I questioned the "need" for a body lift for Expedition and other
"new stuff" ZF swaps on FTE and F150Forum. Just unconvincing
words came back, no pictures. ;)

Maybe the "need" they're so-sure of has mostly to do with their
carpet not laying flat-like-stock anymore? LOL :)

Seems like one guy said the dash is in the way and the shift lever
needs to be bent? Take a look at that crooked dangged T18 Ford
factory lever. ;) Form follows function on shift lever shape, IMO.
The first bend is about 60 degrees and the second bend is about
45 degrees and the little bend at the top is about 30 degrees.
{yeah, I need a better picture to show those bends}

Alvin in AZ
ps-This picture shows the extension I made on the lathe at work
back in '79... (since then I'd like to double that, YMMV?)
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Old 02-19-2013, 07:15 PM   #12
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Could I use the late 80s-mid 90s clutch assembly?


I have a 70s Ford clutch assembly but was going to use it on my NP435 swap in my 79 F150.
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Old 02-19-2013, 08:39 PM   #13
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Bronco Info: '78 Bronco with motor, axles and stuff
The ZF input shaft is larger than the NP435... I used a LuK gold clutch set when I did the swap. I will see if I can get some pics of the mods I did to the pedal to install the hyd clutch in the firewall.
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Old 02-19-2013, 08:42 PM   #14
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Thanks man.

I guess I will find a clutch assembly from a late 80s-mid 90s truck with a manual in it.
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Old 02-21-2013, 10:41 PM   #15
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Quote:
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The ZF input shaft is larger than the NP435...
Are you sure 'bout that? ;)

1+1/16" diameter with ten splines and 17mm pilot snout.
Right or wrong?

Anyway, that's what my 1/2 ton and 3/4 ton stuff had.

Seems like there's some 1+1/4" stuff for diesels or something?

Quote:
I will see if I can get some pics of the mods I did to the pedal
to install the hyd clutch in the firewall.
That'd be cool. :)

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Old 02-21-2013, 10:42 PM   #16
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I wonder if I can use an earlier flywheel for a EFI 460 on my 78-79 460..?

I'm so ready to do this swap since gas is going up.
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Old 02-26-2013, 06:26 PM   #17
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We no one is replying on my build thread so i wl post this here since this forum here is getting more views.





Which of these two clutch pedal assemblies would be best to put in my 79 with the hydraulic set up.


The 79 clutch assembly uses a z bar so that is out of the equation.
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Old 02-26-2013, 08:35 PM   #18
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Quote:
Originally Posted by TheBlackDevil View Post
I wonder if I can use an earlier flywheel for a EFI 460 on my 78-79 460..?

I'm so ready to do this swap since gas is going up.
You need a D8TE flywheel because of the externally balanced crank and the bigger clutch.

Quote:
Originally Posted by TheBlackDevil View Post
We no one is replying on my build thread so i wl post this here since this forum here is getting more views.

Which of these two clutch pedal assemblies would be best to put in my 79 with the hydraulic set up.


The 79 clutch assembly uses a z bar so that is out of the equation.
Use the 79 set and modify the bellcrank lever. You need to cut the bellcrank lever off the new style slutch pedal shaft and weld the tab to the bellcrank on the 79 pedal. Sorry I haven't posted a picture, I'll get on that right now and edit this post with the pictures.







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Old 02-26-2013, 08:42 PM   #19
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Thanks dude. I was planning to buy one of these clutch assemblys. No use to buy them then eh?

I have a DIVE block. So it's internally balanced. I will get the external and have it zero balanced, I guess.
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Old 02-27-2013, 11:39 AM   #20
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Thanks dude.
x2. :)

Cool pictures and explanation of what's needed for the swap. :)

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