Scored a ZF S5-42

Kevin 007

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Scored another ZF S5-42, 4.14 close ratio, 1994 model out of a powerstroke, which I found odd as I thought they came with the 47's. Must have been a 1994 thing. This is the trans that will be going into my 1984 T-19 truck this spring/summer. It was a quiet and good shifting unit but I will be having new bearings and synchros installed at the very least prior to install. It probably will need something else that im unaware of at this point but im preparing for that. This will be done by Coast Powertrain in Kelowna BC.
Then a clutch kit. Im an viewing the other active posts regarding the swap to learn more about which kit I want. Will probably go with the Luk SMF conversion kit.

And to clarify the length of the 4x4 ZF compared to the 4x4 T-19. The ZF is 27'' from bellhousing to mating surface for T-case. The T-19 (including its bellhousing) is between 26 and 27 inches.....hard to be exact with it still in the truck. So Im very happy that I shouldn't have to mess with driveshaft lengths.
 

ToughOldFord

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Congrats! I just did this very conversion on my '85. You won't have to do anything to the drivelines, they bolt right up. You will need the crossmember (with the ears) and the tunnel cover for the ZF.
 

idipwr

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Powerstrokes came with 42's through mid year 1995.
 

lotzagoodstuff

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Do a Lucky Mod: it's cheap and works as long as you drill the holes carefully and on size. One other bonus is that you can be a lot more certain that whatever clutch you get will fit as opposed to the recent "rash" of improperly drilled and balanced SMF :eek:
 

lotzagoodstuff

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Here you go this is how you do this. This is from the guy who came up with this.

The "Lucky Mod"
Changing a Dual-Mass to a Single-Mass Flywheel
By Jim Williams (Lucky Larue)

When taking out the flywheel be careful as this thing is heavy, and it weighs around 65lbs.

One thing if for any reason you have any concerns don't try this . This is at your own risk, Mel Agne has done this conversion and so far it has worked out great, I have not put this in my truck as of yet but have it ready as my flywheel is making noise and I have this ready when I do change the clutch out I will change this out also. I am not afraid of using this fix, I feel really safe doing this to my truck.

I strongly suggest you drill out the bolt holes on a GOOD drill press to make sure the holes are straight. It would not be a bad idea to check the balance after putting it back together before installing it.

There is a guy on E-Bay that has made a DMF hub that dose the very same thing I have done and he wants $200 plus shipping for the hub, that is where I got my idea and tore a flywheel apart and discovered this trick This fix will cost you whatever the price of the 6 grade 8, 3/8 X 2" fine threaded bolts & lock nuts and about an hour of your time drilling out the holes and bolting it all back together once you have the flywheel out.

After removing the flywheel take it all apart and I do mean all apart, remove everything, springs, friction plates and take the hub that bolts to the crank off, 2 small countersunk screws and remove everything in there also, there are some friction plates in it also.
It might be necessary to cut the big springs with an angle grinder, and pop them all out. Once they were out, you can turn the "inner sanctum" which is still held in place at that point by rubber bushings. Some whacks with a hammer and punch allowed it to turn. Once it rotates about 20 degrees, you will see everything will start to fall apart for you.

The part that the pressure plate bolts to, the clutch plate, has 6 holes in the center that also bolts to the flywheel hub, this hub has 6 blind threaded holes that needs to be drilled all the way through I drilled them out to 3/8 even though they were threaded, I thought 3/8 X 2" fine threaded grade 8 bolts would be the right size and would match the holes in the ring gear plate better. , be careful when removing the hub plate that has the blind threaded holes as it is mounted to a center that is a roller bearing and you might pull the bearing apart.You might have problems getting the center bearing to come off the hub, and experience the loose ball syndrome. If indeed you do pull the bearing apart you will need to put the ball bearings back in as to line up everything. Don't worry about the bearing as it will serve no purpose after you bolt the whole thing together.

If you notice on the plate that has the ring gear, there are 9 holes drilled through it. 6 of the holes are smaller and will almost line up with the 6 in the hub you just drilled, you now have to drill the holes in the ring gear plate to match the ones in the hub you just drilled. I did this by bolting the 2 part hub back together on the ring gear plate so the clutch plate would line up true and then put 3 smaller diameter bolts, 5/16" bolts through every other hole I drilled out in the hub and through the smaller holes in the ring gear plate to line every thing up. I ran a 3/8 drill down to drill out 3 of the holes in the ring gear plate, I then put the 3/8 bolts in the 3 holes I just drilled out and tightened them, then drilled out the other 3 holes. I put all grade 8 bolts in and used lock nuts, but do not use the ones with plastic in them but all metal locknut's, torque the nuts to 40 lbs.

The 9 bolts that bolt the flywheel to the crankshaft also goes through the ring gear plate and the clutch plate, the hub now bolts to the ring gear plate so everything is bolted together to make it a single mass. Use a clutch disk with springs in the center to take some of the shock out of the diesel shut down.
Otherwise, it is easier to understand when your looking at the DMF while reading my notes.

No more noise and you can still use you stock clutch setup with the springs in the clutch hub. Hope this is of some value to you. Let me know if you use this and how you like it.

If you have any questions please fell free to ask.

Once again if your clutch disk dose not have the springs in the center you will need to get one that dose. This is to absorb some of the torque and not twist the center out of the clutch disk and help absorbing the torque shock to the transmission on start up and shut down.

Editors Note: Having done this myself, I would personally recommend that you change your ZF transmission fluid from the recommended ATF, to a streight 30wt. motor oil, overfilled to a total of 2 gallons. This will help decrease the low speed gear rattle that is typical of all SMF conversions.
 

ToughOldFord

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Personally I wouldn't do that, jury-rigged repairs are fine to get you home, but they are not a fix. And your flywheel is one thing you don't want grenading on you and it'll do it at the worst possible time, like pulling a load up a steep grade in traffic.
 

jaluhn83

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Yep. The stock flywheel is designed that way for a reason - as I understand it, the main reason is to dampen torsional (rotation) vibrations that would otherwise cause damage to the gears. Pretty much every engine has some form of a damper between the engine and trans for this reason - usually it's incorporated in the clutch hub (the springs you usually see arranged in a circle between plates in the hub portion) but for whatever reason they put them in the flywheel and used a solid clutch disc instead - you lock the flywheel together and you loose this dampening.
 

Kevin 007

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Lotzagoodstuff..thank you for taking the time to post the information. Learn something new everyday!! However, I don't think I will be pursuing this mod myself mostly due to the lack of a good drill press but im sure it could work out if done percisely.

Thanks again.
 

Kevin 007

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What starter will be necessary as this S5-42 is from a PS truck. Will a 7.3 PS starter be compatible with the 6.9 and whatever SMF setup is needed for this swap?

Thanks
 

The Warden

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The starter bolts to the adapter plate, not to the bellhousing...so, you should be good to go with the starter you already have ;Sweet in fact, IIRC when I did the T-19 to ZF swap in my truck, I didn't even have to remove the starter...

{edit} Here's a pic of the engine with the transmission and bellhousing removed, and the starter still in place:

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