Prepping for T-19 to ZF5 Swap

[The Warden]

Hello! Finally get to take a few minutes' breather from school to post this.

Thanks to towcat, I now have a ZF5 that will be seeing its way into my truck after it gets rebuilt. Since this didn't come from a complete donor truck, I now get to start assembling parts.

Any suggestions on a supplier for rebuild parts? Besides the standard bearing/syncro kit, I know I need shift forks and the lower gearshift unit (the one the "main" lever bolts to), and there may be more once it's opened up. My buddy who's doing the rebuild may also need a manual, if the shop at his school doesn't have one.

So far, I know for a fact that I need a gearshift lever and a floor pan insert. I'm going to pull a floor pan insert off a truck tomorrow, and I think I "get" to go junkyard hunting for a gearshift lever. Just wondering, how far off is the cutout for the ZF compared to the T-19?

I've heard in the past that the ZF5 transmission crossmember is different from that on a T-19. I asked towcat about this last night, and he wasn't 100% sure how vastly different it is (been a while since he's had a need to compare the two), so is there anyone who can say either way? Can the one from a T-19 be adapted? What other tranny/engine combos might use the same crossmember?

I clearly also have to re-do the clutch, and it looks like the T-19 flywheel is also a no-go (not necessarily a bad thing; I've been needing to replace the ring gear ever since I got the truck). Any suggestions on what route to go here? towcat has a few old DMFW's (that are probably in need of a Lucky mod), and I may be able to snag one, but if the cost isn't prohibitive, a SMFW conversion sounds like a nice idea.

I know I'm missing something Any input would be greatly appreciated...

Thanks in advance

 

[Agnem]

Sounds to me like you've got it pretty well covered. Not sure if the driveshaft will need to be longer or shorter. Might look into that.

 

[Dsl_Dog_Treat]

I clearly also have to re-do the clutch, and it looks like the T-19 flywheel is also a no-go (not necessarily a bad thing; I've been needing to replace the ring gear ever since I got the truck). Any suggestions on what route to go here? towcat has a few old DMFW's (that are probably in need of a Lucky mod), and I may be able to snag one, but if the cost isn't prohibitive, a SMFW conversion sounds like a nice idea.

I know I'm missing something Any input would be greatly appreciated...

Thanks in advance

Warden,

Do the lucky mod, mucho cheaper. Including a new 3/8' drill bit, my total Lucky mod cost was 12 bux.
I am happy with the mod and will do it again if I acquire another rig.
If ya need a pic of the ZF croos memeber, I would be happy to shoot one for ya. :draw

Good luck on the conversion.

Ron

 

[soulpatchfr]

see if this pic helps you.
i have a few more from diff angles & like Ron - happy to snap any that you need.

 

[The Warden]

Mel, if I'm remembering correctly, the ZF5 is slightly longer than the T-19. However, the length difference is such that the slip yoke can safely accomodate it (at least that's what I think John said on TDS way back when; I seem to recall him ending up using a T-19 driveshaft and winding up needing to get a special U-joint to get it attached to his ZF; thank goodness I won't need to deal with any of that since my 13-45's going behind the ZF ). Also, I am planning on adding an overdrive unit at some point in the distant future (double O/D I figure that that'll give me more versatility than trading the 4.10 gears for 3.54's like I originally wanted to do), so I figure I'll get the driveshafts resized then if the slip yoke can handle the length difference in the meantime, and keep in mind the tranny length difference until that time. I'll measure both trannies at some point in the game before performing the physical swap, though, just to be safe.

Ron and soulpatchfr, thanks for the pic offers Do you guys by chance know if the 2WD crossmember is similar to the 4x4 crossmember? soulpatchfr's pic definitely looks completely different from the crossmember on my T-19 I'm sure I'll be asking for more pics as things progress, but I haven't even looked at the T-19 crossmemebr in any great detail yet...

BTW, I now have the floor pan insert in hand (thanks again towcat) Just need the rebuild components, the crossmember, the gearshift lever, and the clutch stuff now... I spent some time looking on Luk's page, and wanted to double-check...the wider the diameter of the clutch disc, the better, right (due to extra material)? If so, $$ depending, that's leaning me more towards the SMFW...but I still need to figure out how much the clutch stuff is going to cost...

Thanks again

 

[dozer]

warden, I would try Novak for the tranny parts, if they handle ZF5 stuff. They're pretty good guys there...

Towcat, do you have any known-good DMFW's ?? I'm about to tackle the clutch on my 91 zf5 truck, and if I had a good DMFW, I'd be real tempted to just stick with the dmfw and put in a $160 clutch kit for now.

 

[towcat]

warden, I would try Novak for the tranny parts, if they handle ZF5 stuff. They're pretty good guys there...

Towcat, do you have any known-good DMFW's ?? I'm about to tackle the clutch on my 91 zf5 truck, and if I had a good DMFW, I'd be real tempted to just stick with the dmfw and put in a $160 clutch kit for now.

dozer-
All the ones I have have seen towtruck duty. I am not abusive or I would not have seen 3-4years of use out of the clutch but they are used. A lucky conversion is not out of the question since I don't have chatter spots on them and there is no cracks. But the dampening springs are SHOT. Anybody who knows me knows I am a tightfisted SOB. If it is usable, its gonna get used. After all, why would I go through the grief of personally stripping trucks for parts and do all my own work? Good thing is, the DOT cops never have an issue with the trucks or my customers trucks when inspection time rolls around