Zf5-zf6 swap

[Bootzz]

How hard is this swap? Do drive shafts have to be shortened/lengthened or u-joints changed?
Have a zf5 4x4 that I cracked in half and found a 4x4 zf6 for pretty cheap
Does it bolt right up into the zf5's place?

 

[NO_SPRK]

apples to oranges. complicated for a idi. not that bad for a OBS powestroke

 

[79jasper]

Question #1: expensive.
#2: Yes.
#3: Input splines are different IIRC, which means a new clutch disc at least.
Don't forget the zf-6 uses a fluid cooler.

 

[Bootzz]

Ok then
Ima just look for another zf5
They are pretty cheap around here
How hard is it to convert from a 2wd to 4wd?? Is it as easy as taking the tail off and just replacing it with my transfer case?

 

[franklin2]

Ok then
Ima just look for another zf5
They are pretty cheap around here
How hard is it to convert from a 2wd to 4wd?? Is it as easy as taking the tail off and just replacing it with my transfer case?

A 2wd zf from a f450 with the tranny mounted parking brake, yes just take the parking brake off and install your transfer case. A zf from a f250 or f350 2wd, no. It requires a complete tear down to replace the rear shaft and a couple of other things from a 4x4 zf.

 

[trackspeeder]

Question #1: expensive.
#2: Yes.
#3: Input splines are different IIRC, which means a new clutch disc at least.
Don't forget the zf-6 uses a fluid cooler.

Different output shaft.

 

[riotwarrior]

How hard is this swap? Do drive shafts have to be shortened/lengthened or u-joints changed?
Have a zf5 4x4 that I cracked in half and found a 4x4 zf6 for pretty cheap
Does it bolt right up into the zf5's place?

U pay shipping I'll ship a ZF 4wd front half of case to you...where did yours break front or rear half?

Then I pay shipping U send parts I want as swap?

 

[Bootzz]

Hey man txt me
337-654-7291
Not exactly sure what u mean by "half"

 

[riotwarrior]

There is a rear section of the case and a front section they bolt together...I have a good front half of case...and as a matter of fact I've got a good rear section too.

Where is yours BROKEN?

 

[DesertBen44]

I was under the impression the zf6 is Huge in diameter compared to the zf5, and extensive sheet metal mods would be required to fit it into an OBS?

Not firsthand experience, but read that multiple times on multiple forums researching cummins swaps

 

[thx997303]

The zf5 and zf6 transmissions I've seen looked to be very similar in size and shape. I think most of the issues lie in the different input shaft and lack of bell housing adapter on the zf6 stock.

 

[79jasper]

lack of bell housing adapter on the zf6 stock.

That's right.
It is different bell housing, right?

 

[thx997303]

Actually, it seems that the zf5 uses a bell housing adapter to connect to the IDI, but the zf6 doesn't use one to connect to the powerstroke. I'll see if I can't dig up a pic. The bell housing bolt patterns are the same. Though it looks like the zf6 may be larger around the rest of the transmission.

Edit: Here it is. http://www.ford-trucks.com/forums/showpost.php?p=11917796&postcount=29

 

[79jasper]

Okay.
So the 2nd gen Powerstroke doesn't have the spacer/adapter, therefore making the input shaft shorter, which won't reach an idi clutch?

 

[thx997303]

No, the difference that requires the spacer is in the block, the shaft on the. zf6 will reach, but has different splines, so you would need a different clutch.