so how hard is it to take a four speed truck and make it a five speed? How many hours are invested in this? I have all the zf crossmembers shifters pedals etc. Will i need to use the transfer case that came with the zf or can i use the one thats bolted to the 4 spd? Can i use the four speed's transmission tunnel cover with the five speed?
You can use the 13-45 transfer case with the ZF; in fact, IMHO it's easier that way, since this means you won't need to do any driveshaft modifications and you can reuse the same U-joints. The transmission tunnel cover from the T-19 will not fit around the ZF as it sits. It might be possible to bend it into shape with a BFH, but IMHO it would be much easier to use one meant for a ZF. Take a look at the attached pictures to see the difference between the two. You do NOT need to replace the pedal assembly or the clutch hydraulics. In fact, (assuming you have an '80-'86 truck and the pedal assembly came out of an '87-'91 truck) you actually won't be able to use the pedal assembly that you pulled out. I don't know if the 13-56 transfer case shift lever will work with the 13-45, but if you reuse the shift lever assembly from the 13-45, you'll need to cut a hole in the ZF transmission tunnel cover. Not a big deal, but still needs to be done.
Will i need new drive shafts? I have the one from the f350 zf setup
If you reuse the 13-45 transfer case, you do NOT need new driveshafts. The 4x4 ZF is even the same length as the 4x4 T-19.
Also will a van 6.9 fit where a truck 6.9 is if i use some of the stuff off the truck engine to make it work?
Yes, it will. You'll need to move the oil cooler and one of the exhaust manifolds over (I don't remember off the top of my head which one), but IIRC there's nothing else that NEEDS to be done. The fuel filter's located in a different spot on the van, but you can leave it there if you want.
If i were to do and engine swap and the zf five speed swap how many hours would that take?
Not sure on time...I've never done an engine swap, but the T-19/ZF swap can probably be done in a solid day of working. Mine was done by a friend of mine on his college auto shop rack over the course of two days.
Also what usually is wrong when a tach gauge and rear tank fuel gauge dont work? Hours to fix?
Probably sending units in both cases. The tach gauge sender's a simple job; you could probably have it done in 10 minutes or so. The sender's on the IP drive gear cover near the oil filler pipe. The rear tank fuel gauge's another story....you'll either need to drop the rear fuel tank or pull the bed. I don't know for sure how long it'll take to fix, but it'll take quite a while.
Any thing else i am missing?
I think you've got your bases covered, although I'll probably remember something 5 minutes after posting this, or someone else will remember something I forgot
One thing....what are you doing about your clutch? Are you getting an SMF, or doing a DMF with a Lucky mod, or taking your chances with a "normal" DMF? Also, I would recommend a Kevlar pilot bushing over a metal pilot bearing...it'll last a long longer. Well worth the $30 IMHO.
Hope this helps some...good luck!
