Cracked T19 belhousing and popping out of first...ZF5 or fix?

WrenchWhore

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What do you guys think? How much is it going to cost to get a ZF5 into my truck in 2022? I found one is CA that about 800 but not sure if it's a gas or diesel version. Should I just make a support bracket and keep on truckin with the T19? Clutch still works...for now but i'm sure it's going to snap off soon. Funds are tight and I don't mind the swap itself but not sure I want to blow $1500 minimum on swapping to a 5 speed in a 4x4. I'll upload some pics so you guys can seen the damage.
 

Austin86250

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well it depends on what speed you normally drive if you keep it about 65 or under t19 will suit you needs but if your on the freeway often just absolutely smashing the governor at 80 you'll make your money back in diesel in no time

as for gas vs diesel trans the gas trans can be modified to work on diesel i think you just drill out the top 2 holes but people like the lower gear of the gas trans better
 

Jesus Freak

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I'd shore up the T19. There's a couple threads about modifying a gas ZF5, it's pretty controversial. I'd hold out for a diesel zf5. I put a zf5 in my 86, I like it. At 2200rpms I'm doing 60, and that's my speed. I wouldn't have done the ZF5, but I scored one for free so I rolled with it.
 

Jesus Freak

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Why couldn't you just have your bellhousing welded? It's aluminum, right?
It really seems to be a common thing on these bell housings right now. I've got 2 of these and one of them is broke like everyone discribed(they're not in trucks, just occupying my carport). Welding would be a good idea, but in the long term I think fabricating a steel bracket that would attach to the two transmission to bell housing bolts and give the clutchs pivot pin a little more strength would be a good investment.
 

Jesus Freak

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This must be from age. I don't remember seeing cracks there before. I'm pretty sure that the one I have in my garage isn't cracked. That one hasn't been used since 2006.
There was a thread less than a month ago about it. I guess like how 7.3idi owners started learning about cavitation in the late 90s, t19 owners are learning about bell housings.......40yrs later.
 

WrenchWhore

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I think the issue truly is wear and tear and the lack of lube on the throw out bearing as well as the pivot ball. Once it's starts getting dry and hard to push it transfers all that hydraulic pressure to the pivot. It's really not that thick of aluminum either. I love the T19 for 95% of my driving BUT I would absolutely love a ZF5 for that highway cruise and fuel mileage. If only they had a cast iron diesel bell housing for the T19. Probably would never have a problem. I can spiff up the T19 belhousings/transmission and add a bracket but it's also the "well this failed and this is failing so might as well upgrade" mentality. Plus i've been on the highway here in AZ and the normal speed limit is 75mph. Even the semi trucks run this speed on the regular. I just hate paying dumb amounts of money for questionable used parts especially one that's known for cracking in the 4x4 configuration. I've never heard of T19's cracking the case but i've sure heard that from the ZF5. To be honest I think the Ranger OD is were it's really at (too bad it's discontinued) OD and the ability to split all your gears however you see fit. Add a transfer-case to that equation and you're semi truck territory for gear choices. I understand that most guys don't need all those gears but I figure the more the merrier. I think I will add a bracket in the mean time and search for another transmission OR belhousing but i'm still pretty indecisive on the whole deal.
 

WrenchWhore

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It really seems to be a common thing on these bell housings right now. I've got 2 of these and one of them is broke like everyone discribed(they're not in trucks, just occupying my carport). Welding would be a good idea, but in the long term I think fabricating a steel bracket that would attach to the two transmission to bell housing bolts and give the clutchs pivot pin a little more strength would be a good investment.
I've got a picture of it I just need to upload it. The material broke and fell out on the top and bottom and just the material that supports the pivot ball is left and the clutch still works. I do have a welder but it's just MIG I can weld steel all day but just not set up for aluminum.
 

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Jesus Freak

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I think the issue truly is wear and tear and the lack of lube on the throw out bearing as well as the pivot ball. Once it's starts getting dry and hard to push it transfers all that hydraulic pressure to the pivot. It's really not that thick of aluminum either. I love the T19 for 95% of my driving BUT I would absolutely love a ZF5 for that highway cruise and fuel mileage. If only they had a cast iron diesel bell housing for the T19. Probably would never have a problem. I can spiff up the T19 belhousings/transmission and add a bracket but it's also the "well this failed and this is failing so might as well upgrade" mentality. Plus i've been on the highway here in AZ and the normal speed limit is 75mph. Even the semi trucks run this speed on the regular. I just hate paying dumb amounts of money for questionable used parts especially one that's known for cracking in the 4x4 configuration. I've never heard of T19's cracking the case but i've sure heard that from the ZF5.
Yeah, money is hard to come by so I hate spending it. When I got my 86 it had a C6 and a gear vendor. I didn't trust the GV, sometimes it wouldn't come out of OD when I was slowing down and my whole truck would start this shimmy shake thing and make me a nervous wreck.
And if you want to do 75mph with a zf5, definitely put a 3.55 gear in the rear end. I've got 4.10 and Im 2200rpm doing 60, I wouldn't be a fan of having my truck wound up that tight just to keep up with traffic. But as I said earlier, I hate spending money and I don't have a lot of it so I baby all my stuff.
 

u2slow

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I'd do the ZF... but maybe that's because diesel S42's have been easier to find (for me - at $100-250ish). Gas ones are tough tho.
 

WrenchWhore

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Yeah, money is hard to come by so I hate spending it. When I got my 86 it had a C6 and a gear vendor. I didn't trust the GV, sometimes it wouldn't come out of OD when I was slowing down and my whole truck would start this shimmy shake thing and make me a nervous wreck.
And if you want to do 75mph with a zf5, definitely put a 3.55 gear in the rear end. I've got 4.10 and Im 2200rpm doing 60, I wouldn't be a fan of having my truck wound up that tight just to keep up with traffic. But as I said earlier, I hate spending money and I don't have a lot of it so I baby all my stuff.
I currently have 3.55 gears in the truck and 35's so highway speeds are not as bad but it does rev higher than i'd like. I think the zf5 with 4:10's and 35's would be a great match. I'd like to come up on a ZF5 but I can't seem to find one at all really let alone a diesel 4x4 trans. I will just have to keep the search going for the right one. I should put a bug in my local junkyards ear and see if they turn one up.
You can get a spool gun for your mig welder. That will allow you to do aluminum.
I could add that to my setup but it's about 275 before shipping to add a spool gun to my Hobart 210 MVP
I'd do the ZF... but maybe that's because diesel S42's have been easier to find (for me - at $100-250ish). Gas ones are tough tho.
Where are you finding these trucks? Just local junkyards or online?
 

Jesus Freak

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I'd do the ZF... but maybe that's because diesel S42's have been easier to find (for me - at $100-250ish). Gas ones are tough tho.
This is part of my theory about these trucks just barely spilling out of Canada and piling up in the west corner there. It seems like most of y'all are up there in the North West. Those transmissions are as rare as hen's teeth down here.
 

ROCK HARVEY

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I have a zf5 in my 4x4 with 4.10s and 35” tires. I really like the 5th gear, I would definitely hate to not have it. Around here (Ohio) zf5s come up for sale once every couple months, usually for 600-800. If you go that route, definitely inspect it closely for cracks. I had to replace mine recently because the tailhousing had a huge crack. They always seem to crack in the same place due to carrying the weight of the transfer case, especially if the transmission mount has gone bad.

I actually have the gasser gears in my current transmission. I swapped my diesel bellhousing over, rather than drill my gasser bellhousing to fit the diesel. There’s more to it than drilling the top two bolts, there is a tech article about it if you end up finding a gasser trans and want to convert it. If you do swap to a zf5 I have a solid flywheel conversion kit that I would sell for cheap, shipping would be expensive to AZ though.
 

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