ZF5 install parts list

Big Slim · Dec 21, 2020

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 · Dec 21, 2020

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

Tim

Big Slim · Dec 21, 2020

oh. yea i already have that as well.

hankjr · Dec 21, 2020

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 · Dec 21, 2020

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

Timmy390 · Dec 21, 2020

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 · Dec 21, 2020

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

Big Slim · Dec 29, 2020

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 · Dec 30, 2020

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 · Dec 30, 2020

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 · Dec 30, 2020

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