ZF5 install parts list

[Big Slim]

I have a zf trans and transfer case with transfer case adapter and twin stick already (ill put these on the list for others). i was not able to find a complete list of parts. here is what i have found that i need to get:
1. master cylinder (18mm) f250 stock
2. slave cylinder (internal) stock
3. Hose between the cylinder. i see there is a braided one on rockauto. the others look pre-bent, so i assume its not right for this application. https://www.rockauto.com/en/moreinfo.php?pk=10898452&cc=1125021&jsn=11226
4. F250 clutch (multi finger, not the 3 finger). anyone know if i need the series dampend clutch. i imagine it makes smoother shift like a dual mass flywheel.
5. back up switch plug
6. maybe a longer speedo cable? where to find?
7. correct length drive shafts.
8. twin stick shifter. seem that everyone likes the JBFab stainless one.
9. transfer case adapter (to use Dana 20 on the ZF). Or others have said the NP205 works well with this swap.
10. Shifter boots
11. gasket between the trans and transfer case. (if didnt buy the adapter kit that has it)

mods needed:
1. modify the clutch pedal, or push rod, to accept the new master cylinder. found good info on this part here: https://classicbroncos.com/forums/showthread.php?t=287069&highlight=zf5+master+slave+cylinder&page=2
2. new cutout for trans shifter and transfer case shifter. i could not find a thread on locations or size of these cut outs.
3. make a shifter to clear the dash. using bent steel rod.
4. make a transmission mount cross member. i have only seen the bcbroncos one for sale. i did see some threads that this one mounted the trans crooked and had to be modified.

any help updating this list or links to threads would be helpful. hopefully will make the swap a bit easier and quicker.

 

[Timmy390]

I didn't see Twin Sticks on your list.....going to need those.....

Tim

 

[Big Slim]

oh. yea i already have that as well.

 

[hankjr]

Howdy. you have EFI or no? BC Broncos sells a speedo cable that will plug into a speed sensor.

this might be a source if you not using EFI;

https://speedometercablesusa.com/cables_and_housing_assembly.html

i used a braided clutch hose but dont recall where i bought it. have to think on it

Hank

 

[Big Slim]

thanks. right now i do not have EFI. i wanted to tackle the trans first. i do have a explorer motor.

 

[Timmy390]

I'm just buying the BC kit. It's $860 but far as I can tell they are not selling the cross member outside of the kit.

I found I could save a few bucks by sourcing everything myself but the cross member is the sticking point.

I have a M5ODR2 sitting waiting to go in

Tim

 

[Jedeka]

Timmy390, I am going to use the same transmission. My kit from BC showed up over the weekend.

 

[Big Slim]

i got the old trans out and looks like i need a new flywheel as well. so i need a flywheel from a '69 302 bronco right, and not from a '96 where the trans came out of? 157 or 164 tooth?

 

[Bitch'nBronco]

Not sure how many teeth but I have a 70 302 flywheel with centerforce ii clutch on my ZF. I used a hall effect electric speed sensor ( i can get you the part number if you want to go that route. Don't forget, you're going to need to shorten the rear drive shaft and lengthen the front one in most cases. The ZF trans is pretty long.

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[Bitch'nBronco]

Also if you're getting twin sticks and haven't ordered them yet, jbfab has a nice set and has a ZF shifter as well. Its all stainless and can be bent if needed. Mine didn't need any bedding, it's maybe 2 inches from the bottom of the dash at its closest point.

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[Bitch'nBronco]

Here are some install pics, let me know if you need any measurements or have questions. Happy to help, been running my ZF/205 combo for 4 years with little to no issues

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[hankjr]

Here are some install pics, let me know if you need any measurements or have questions. Happy to help, been running my ZF/205 combo for 4 years with little to no issues

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Where do those twins come up through the tunnel?

Thx

Hank

 

[Bitch'nBronco]

Pretty close to the stock location, you will have to open the hole up about an inch towards the firewall to get your low gears to engage

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[Bitch'nBronco]

I don't have the measurements anymore but this is the tunnel cover I made. I know the hole for the ZF shifter is 6"×7"

The trans shift hole starts right where the trans tunnel bends up for the firewall

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[Mikes Early Bronco]

Thank you

I'm ordering the BC Broncos ZF kit tomorrow minus the adapter because I have an NP205. Boy am I glad I found this thread.

 

[Bitch'nBronco]

I think the 205 is the way to go for the ZF swap. I recommend the JBfab adjustable NP205 shift detents even if you don't twin stick it. The detents make it shift really nicely.

You'll have to grind the transfercase mounting flange on the zf to make clearance for the rear wheel drive shift rail. You'll also have to swap the rwd yoke, I got mine from advanced adapters to work with the Bronco rear drive shaft. The part number for the seal is printed on the seal in the photo

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[Bitch'nBronco]

I'm pretty sure this is the yoke I bought to run the 1310 CV joint from the rear Bronco drive shaft

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[Mikes Early Bronco]

Thanks again

Perfect. This is all great info. I have the next few days off. I can’t wait to get to work. Thank you.

 

[Mikes Early Bronco]

will a 3.5 in suspension lift work with the ZF5's driveshaft angle?

I almost ordered my lift today but I'm concerned that the 3.5 suspension lift that I want might add too much angle to the rear driveshaft since I'm using the ZF setup. I'll be adding a 2 inch body lift to cover the need for space above the ZF. I'm ordering driveshafts after I get it measured up. Do you think I'd be safe with a 3.5 in lift? I can go 2.5 but prefer the clearance of the 3.5. I might move the rear axle back an inch. trying to think outside the box to get a better angle. Thanks.

P.S. I recently changed my screen name from sixrrr to the one I have on Facebook.

 

[Btempy]

With the 3.5" if you didn't order a shim you're gonna need one! I have WH 11 leaf packs and a 6 degree shim.

Also I'm one of the ones with the bc crossmember. I had to cut and re-welded the mount to get everything centered, however if you're running a 205 you might want to leave it alone.