ZF-5 Questions/Conversion

[dnoellsch]

I have a 1994 F-250 4x2 with an E40D that is going bad and am wanting to convert it to a ZF-5 transmission. A couple of questions I had.... the transmission that my buddy has is from a 4x4 and I have a 4x2 that I have no intention of making a 4x4. Will this tranmission work or do I need a different extension housing? If so, how easy is it to get one? Or am I better off just continuing my search for a different one made for a 4x2? I don't typically get a chance at a manual so I would really like to make this one work if possible.

Thanks,
David

 

[The Warden]

Short of completely disassembling the tranny to replace the tailshaft housing, no, you can't use a 4x4 tranny on a 4x2. If you REALLY want that tranny, you could put it and the transfer case on the truck and just not put in a front drivetrain and let the transfer case be a dead weight (although you COULD use 4L as a 2WD Low gear ), but I would recommend forgetting about that tranny and finding a 2WD ZF5.

Of course, part of this is that you NEED to find a ZF5 out of a diesel; the g@$ ZF has a slightly different bellhousing bolt pattern.

Sorry to be the bearer of bad news...good luck in your search!

 

[Ceejmo]

You would think that the tail housing would be easy to remove BUT, If I recall correctly everything comes off from the other end.

Here is alot of notes and information that I gathered when I did my conversion.

 

[dnoellsch]

Warden,

I was afraid that would be the case... I guess I will continue my search. I would really hate to put the money into this E40D when my tech says it might fail again. Besides I wanted a manual from the beginning. I just have to be patient I guess.

Ceejmo,

Thanks for the awesome file collection. This will make things so much easier. That zip file covers about every detail that I hadn't even considered yet. Very nice!

If anyone has a ZF-5 for a 4x2 or knows where one is, please let me know.

Thanks,
David

 

[dnoellsch]

Ceejmo,

I was also wondering, you stated that you used a S5-47 model ZF-5 in you conversion, so will a S5-42 work? Also, will a S5-42 that is from a 1997 fit (I would assume so)?

Thanks,
David