Clutch Kit Suggestions for ZF5 Swap

I’ve finally gotten my hands on a ZF5 and turbo for my truck, and it’s left me with a tight budget. After searching through a few threads, it seems like there isn’t much consensus on what all can be re-used in the process. With that being said, I’m trying to get a parts list together for the cheapest clutch kit humanly possible.

I plan to go with an SMF, but once again, I’ve read conflicting stories about whether or not much of the original T19’s components can swap over. The ZF5 I got has a fork and a clutch release bearing on it right now, so I’ve got to work from there. It seems the clutch hydraulics can be re-used, but no valid confirmation on that either. I could go look for a junkyard ZF5, but those aren’t easy to find it seems. Any advice or suggestions/write up would be appreciated.

Cheapest way to go is if you have a original dual mass flywheel. You can do the Lucky Mod to the flywheel, and then buy a clutch disc with springs in it. It's what I have been running 15 years now with no trouble. It is noisy.

But you do not have a flywheel at all, the 4 speed one won't work. When I did mine years ago, stuff wasn't as cheap. They now have conversion kits with the flywheel, pressure plate, the disc, throwout bearing, pilot bearing and the bolts. I just looked on rockauto, one for my 1989 is $232.79. It's hard to beat that, and it's a larger 12 inch clutch. You won't be able to use your flywheel cover because of the larger diameter, but I have run many cars and trucks including my diesel, without a cover for years with no problems.

franklin2 said:

Cheapest way to go is if you have a original dual mass flywheel. You can do the Lucky Mod to the flywheel, and then buy a clutch disc with springs in it. It's what I have been running 15 years now with no trouble. It is noisy.

But you do not have a flywheel at all, the 4 speed one won't work. When I did mine years ago, stuff wasn't as cheap. They now have conversion kits with the flywheel, pressure plate, the disc, throwout bearing, pilot bearing and the bolts. I just looked on rockauto, one for my 1989 is $232.79. It's hard to beat that, and it's a larger 12 inch clutch. You won't be able to use your flywheel cover because of the larger diameter, but I have run many cars and trucks including my diesel, without a cover for years with no problems.

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I’d greatly appreciate it if you could send the link for the clutch kit you mentioned, I’ve only seen kits in the $300+ range so far in my searching. I did see a swap video where the old flywheel plate swapped over with no hassle. Worst case scenario, I bastardize it with a torch and make it work. I’m not very tempted to run without a cover, I live miles from the nearest paved road and the truck spends most of its time on B-Service roads or fields.

I just did a C6 to zf5 swap in my 86' 6.9. Someone told me to use a 6.9, 4speed flywheel behind my 6.9 for balance purposes (bullcrap, you can use the SMF conversion or the 7.3 DMF on the 6.9). I did and modified my clutch fork to compensate for the thinner 6.9 flywheel (I work at a welding shop and was able to figure it out, but this is why everyone says the 4speed flywheel won't work). I basically built up/spaced up on both ends of my clutch fork as the pressure plate fingers are further away from the TO bearing because of the thinner 6.9 flywheel. See pics of stock fork and modified fork; plus pic of installed fork up against the back of the TO bearing. It worked fine. It actually revved quicker as the 4speed flywheel probably weighs half to 2/3 of the DMF.

It worked *****'n, no problems what so ever, except for the amount of gear roll over noise coming from tranny at idle. It wasn't that bad in the cab, but as soon as I opened my door it got loud. When driving, no noise at all as soon as rpms went up a little. It bugged me too much so I found a used DMF and now it's quiet at idle and all I hear is engine and exhaust. With the 4speed flywheel, I ran the clutch disc with only one set of springs. I bet if you got a single mass conversion clutch disc with two sets of springs, it would quiet it down some.

So I have basically everything else you need to get your conversion rolling:

freshly surfaced/machined 6.9 flywheel, with new USA input shaft bearing installed
used clutch disc (but I'd recommend getting the dual spring clutch disc to prevent excessive noise)
used pressure plate
used TO bearing
used master + slave cylinder I got with my zf5 (I bought new units, but guy said they worked)
modified clutch fork to make all these parts work together

I'd make you a deal on all these parts, but shipping is going to be expensive as I'm in CA. The $232 SMF conversion kit is so cheap, but I've seen more bad reviews than good ones. There's another SMF conversion kit for $300 that has good reviews, but I guess it depends on your budget.

Hit me up if you're interested or have any questions. I'd be happy to help as I also replaced my 6.9 with another low mile, rebuilt 6.9 at the same time. I'm finally getting this 4x4 dually flatbed up and running. Bought it with bad motor almost 15 years ago!! Also have two diesel, 85' and 88' parts trucks.

Chris
805 748 8564

LUK 07-225

I love it. It’s held up for about 4 years. The last 2 it’s slipped but That’s just in 4th after 20 pounds of boost lol